Micro and Nano Machining of Engineering Materials (eBook)

Kaushik Kumar is an Associate Professor in the Department of Mechanical Engineering, Birla Institute of Technology, Mesra, Ranchi, India. His areas of teaching and research interest are Quality Management Systems, Optimization, Non-conventional machining, CAD / CAM, Rapid Prototyping and Composites. Divya Zindani is pursuing his PhD studies at the National Institute of Technology, Silchar, India. His areas of interests are Manufacturing Processes, Material Selection, Optimization, Product and Process Design, CAD/CAM/CAE and Rapid prototyping.  Nisha Kumari is pursuing her Ph.D studies at Birla Institute of Technology, Mesra, India. Her areas of interests are Bio-mechanics, Product and Process Design, CAD/CAM/CAE and Rapid Prototyping and optimization.   J. Paulo Davim is Eur Ing by FEANI and Senior Chartered Engineer by the Portuguese Institution of Engineers with a MBA and Specialist title in Engineering and Industrial Management. He is a Professor at the Department of Mechanical Engineering of the University of Aveiro. He has more than 30 years of teaching and research experience in Manufacturing, Materials and Mechanical Engineering with special emphasis in Machining & Tribology. He has also interest in Management/Industrial Engineering and Higher Education for Sustainability/Engineering Education. 

Preface 6
Contents 10
About the Editors 11
Overview of Micro and Nano Machining 13
1 Recent Trends in Micro and Nano Machining of Engineering Materials 14
1 Introduction 14
2 Micro Machining with Electrical Discharge Machining Process 14
3 Micro Machining with Electro Chemical Machining Process 16
4 Micro Machining with Abrasive Water Jet Machining Process 17
5 Micro Machining with Laser Beam Machining Process 17
6 Nano Machining with Unconventional Machining Process 18
References 18
2 Micro and Nano Machining—An Industrial Perspective 20
1 Introduction 20
2 Micro and Nano Processes Classification 23
3 Lithography-Based Processes 24
4 Photolithography 25
5 Next-Generation Lithography (NGL) 26
6 Non-lithography-Based Processes 30
7 Mechanical Processes 31
8 Electro-Thermal and Thermal Processes 32
9 Electrochemical Processes 34
10 Nanofabrication Methods 35
11 Future Scope 36
12 Conclusions 37
References 37
Micro and Nano Machining with Conventional Machining Techniques 41
3 Micromachining of Titanium Alloys 42
1 Introduction 42
2 Conventional Micromachining of Titanium Alloys 44
2.1 Micro-Milling of Titanium Alloys 44
2.2 Micro-Drilling of Titanium Alloys 48
2.3 Micro-Turning of Titanium Alloys 49
2.4 Micro-Grinding of Titanium Alloys 51
3 Nonconventional Micromachining of Titanium Alloys 53
3.1 Micro-Electrical Discharge Machining of Titanium Alloys 53
3.2 Electrochemical Micromachining of Titanium Alloys 57
3.3 Laser Micromachining of Titanium Alloys 60
3.4 Abrasive Water-Jet Micromachining of Titanium Alloys 65
4 Conclusions and Future Outlook 66
References 68
4 Ultra-precision Diamond Turning Process 73
1 Introduction 73
2 Ultra-Precision Diamond Turning Configuration 75
3 Materials and Their Applications 75
4 Single Point Cutting Diamond Tools 78
5 Material Removal Mechanism 82
6 Process Parameters for Ultra-Precision Machining 84
6.1 Tool Setting 84
6.2 Component Mounting Fixtures 85
6.3 Selection of Machining Parameters 87
6.4 Tool Path Generation and Compensation 89
6.4.1 Tool Path Generation for Symmetric Surface 90
6.4.2 Tool Path Generation for Non-rotationally Symmetric Surface 90
6.4.3 Tool Path Generation for Micro-structured Surface 91
6.4.4 Tool Path Compensation 92
6.5 Effects of Uncontrollable Parameters 93
7 Metrology of Diamond Turned Surfaces 94
7.1 Surface Finish 96
7.1.1 Important Amplitude-Based Parameters 96
7.1.2 Frequency Domain Power Spectral Density Analysis 97
7.1.3 Autocorrelation 98
7.2 Surface Form Characterization 99
7.3 Surface Measurement Techniques 99
8 Conclusion 100
References 100
Micro and Nano Machining with Non Conventional Machining Techniques 106
5 Abrasive Waterjet Cutting of Lanthanum Phosphate—Yttria Composite: A Comparative Approach 107
1 Introduction 107
2 Materials and Method 108
2.1 Material Preparation 108
2.2 Methods 110
2.3 Material Characterization 112
2.3.1 X-Ray Diffraction Study 112
2.3.2 Micro-Structural Characterization Studies 112
3 Results and Discussion 112
3.1 X-Ray Diffraction 112
3.2 Energy Dispersive X-Ray Spectroscopy (EDS) 113
3.3 Effect of Abrasives on MRR 113
3.4 Effect of Abrasives on KA 115
3.5 Effect of Abrasive Particles on Ra 118
3.6 Influence of Process Parameters Over Different Abrasives 120
4 Micro-Structural Characterization Study 121
4.1 Characterization Studies on SiC Machined Surfaces 121
4.2 Characterization Studies on Garnet Machined Surfaces 122
5 Conclusion 123
Acknowledgements 124
References 124
6 Laser Micromachining of Engineering Materials—A Review 126
1 Introduction 126
2 Literature Review 127
3 Types of Lasers Used in LBMM 131
4 Methodology and Mechanism 132
5 Applications of LBMM 134
5.1 Hole Drilling 134
5.2 Microvia Hole Drilling in Circuit Interconnection 134
5.3 Inkjet Printers Nozzle Drilling 135
5.4 Biomedical Devices 135
5.5 Hole Drilling in Aircraft Engine Components 135
6 Numerical Analysis of Laser Microdrilling 136
6.1 Laser Direct Writing 136
6.2 Submicron/Nano Machining Using Ultrashort Laser 137
7 Recent Advancements in Laser Micromachining 137
8 Conclusion 138
References 138
7 Experimental Analysis of Wire EDM Process Parameters for Micromachining of High Carbon High Chromium Steel by Using MOORA Technique 142
1 Introduction 142
2 Methods and Material 144
2.1 MOORA Methodology 144
2.2 Analysis of Variance 145
3 Material 146
4 Experimentation 146
5 Result and Discussion 149
6 Conclusions 152
References 153
Index 154