Hybrid Micro-Machining Processes

76 Pages·2019·1.626 MB·English

by  Sumit Bhowmik, Divya Zindani

SPRINGER BRIEFS IN
APPLIED SCIENCES AND TECHNOLOGY
Sumit Bhowmik
Divya Zindani
Hybrid Micro-
Machining
Processes
123
SpringerBriefs in Applied Sciences
and Technology
SpringerBriefs present concise summaries of cutting-edge research and practical
applications across a wide spectrum offields. Featuring compact volumes of 50 to
125 pages, the series covers a range of content from professional to academic.
Typical publications can be:
(cid:129) A timely report of state-of-the art methods
(cid:129) Anintroductiontooramanualfortheapplicationofmathematicalorcomputer
techniques
(cid:129) A bridge between new research results, as published in journal articles
(cid:129) A snapshot of a hot or emerging topic
(cid:129) An in-depth case study
(cid:129) Apresentation ofcore conceptsthatstudents mustunderstand inordertomake
independent contributions
SpringerBriefs are characterized by fast, global electronic dissemination,
standard publishing contracts, standardized manuscript preparation and formatting
guidelines, and expedited production schedules.
On the one hand, SpringerBriefs in Applied Sciences and Technology are
devoted to the publication of fundamentals and applications within the different
classical engineering disciplines as well as in interdisciplinary fields that recently
emerged between these areas. On the other hand, as the boundary separating
fundamental research and applied technology is more and more dissolving, this
series isparticularlyopentotrans-disciplinary topics between fundamentalscience
and engineering.
Indexed by EI-Compendex, SCOPUS and Springerlink.
More information about this series at http://www.springer.com/series/8884
Sumit Bhowmik Divya Zindani
(cid:129)
Hybrid Micro-Machining
Processes
123
Sumit Bhowmik DivyaZindani
Department ofMechanical Engineering Department ofMechanical Engineering
National Institute ofTechnology Silchar National Institute ofTechnology Silchar
Silchar, Assam, India Silchar, Assam, India
ISSN 2191-530X ISSN 2191-5318 (electronic)
SpringerBriefs inApplied SciencesandTechnology
ISBN978-3-030-13038-1 ISBN978-3-030-13039-8 (eBook)
https://doi.org/10.1007/978-3-030-13039-8
LibraryofCongressControlNumber:2019931521
©TheAuthor(s),underexclusivelicensetoSpringerNatureSwitzerlandAG2019
Thisworkissubjecttocopyright.AllrightsaresolelyandexclusivelylicensedbythePublisher,whether
thewholeorpartofthematerialisconcerned,specificallytherightsoftranslation,reprinting,reuseof
illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and
transmissionorinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilar
ordissimilarmethodologynowknownorhereafterdeveloped.
The use of general descriptive names, registered names, trademarks, service marks, etc. in this
publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfrom
therelevantprotectivelawsandregulationsandthereforefreeforgeneraluse.
The publisher, the authors and the editors are safe to assume that the advice and information in this
book are believed to be true and accurate at the date of publication. Neither the publisher nor the
authorsortheeditorsgiveawarranty,expressorimplied,withrespecttothematerialcontainedhereinor
for any errors or omissions that may have been made. The publisher remains neutral with regard to
jurisdictionalclaimsinpublishedmapsandinstitutionalaffiliations.
ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG
Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland
Contents
1 Overview of Hybrid Micro-manufacturing Processes . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Classification of Hybrid Micro-manufacturing Processes. . . . . . . . 2
1.2.1 Compound Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.2 Energy-Assisted Micromachining Processes. . . . . . . . . . . . 4
1.2.3 Combined Hybrid Micromachining Processes . . . . . . . . . . 8
1.3 Future Research Opportunities. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Laser-Assisted Micromachining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Conceptual Framework to Laser Beam Micromachining
(LBMM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Mechanism and Principle of Laser Ablation. . . . . . . . . . . . . . . . . 17
2.3.1 Laser Ablation Process Through Nanosecond Laser. . . . . . 17
2.3.2 Laser Ablation Process Through Picosecond Laser . . . . . . 18
2.3.3 Laser Ablation Process Through Femtosecond Laser . . . . . 18
2.4 Laser-Assisted Variant of Hybrid Micromachining Process . . . . . . 20
2.4.1 Laser Beam Assisted Water Jet Micromachining . . . . . . . . 20
2.4.2 Laser Beam Assisted Jet Electrochemical
Micromachining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.3 Laser Beam Assisted Micro-milling/Grinding Process . . . . 22
2.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Magnetic Field Assisted Micro-EDM . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Electrical Discharge Machining (EDM) and Micro-EDM
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
v
vi Contents
3.3 Micro-EDM Process and Its Mechanics . . . . . . . . . . . . . . . . . . . . 29
3.3.1 Mechanism of Material Removal . . . . . . . . . . . . . . . . . . . 29
3.3.2 Process Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4 Working Mechanism of Magnetic Field Assisted Micro-EDM
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Electrorheological Fluid-Assisted Micro-USM. . . . . . . . . . . . . . . . . . 39
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Overview of Micro-USM Process . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3 Chippings and Their Generation . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.4 Electrorheological Fluid-Assisted Micro-USM . . . . . . . . . . . . . . . 42
4.5 Other Fluid-Assisted Micromachining Techniques . . . . . . . . . . . . 44
4.5.1 Chemical-Assisted Micromachining . . . . . . . . . . . . . . . . . 44
4.5.2 Gas-Assisted Variant of Hybrid Micromachining. . . . . . . . 45
4.5.3 Water-Assisted Micromachining . . . . . . . . . . . . . . . . . . . . 46
4.6 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5 Other Assisted Hybrid Micromachining Processes . . . . . . . . . . . . . . 49
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2 Vibration-Assisted Micromachining. . . . . . . . . . . . . . . . . . . . . . . 50
5.2.1 Tool Vibration Assisted Variant of Hybrid
Micromachining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2.2 Workpiece Vibration Assisted Micromachining . . . . . . . . . 52
5.2.3 Work Fluid Vibration Assisted Micromachining . . . . . . . . 53
5.2.4 Objective Lens Vibration Assisted Micromachining. . . . . . 53
5.3 External Electric Field Assisted Variant of Hybrid
Micromachining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.4 Carbon Nanofibre-Assisted Micromachining. . . . . . . . . . . . . . . . . 55
5.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6 Combined Variant of Hybrid Micromachining Processes . . . . . . . . . 61
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.2 Laser Micro-drilling and Jet Electrochemical Machining. . . . . . . . 62
6.3 Micro-electrochemical Machining Combined with
Micro-mechanical Grinding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.4 Micro-electrochemical Discharge Machining . . . . . . . . . . . . . . . . 64
6.5 Simultaneous Micro-electrical Discharge Machining
and Micro-electrochemical Machining . . . . . . . . . . . . . . . . . . . . . 65
Contents vii
6.6 Micro-electrical Discharge Machining Combined
with Electrorheological Fluid-Assisted Polishing. . . . . . . . . . . . . . 65
6.7 Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.8 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Chapter 1
Overview of Hybrid
Micro-manufacturing Processes
1.1 Introduction
There has been a burgeoning demand for micro-components/products in various
industrieswithvarieddomainsofinterestsuchasoptical,aviation,electronics,avi-
ation, and biomedical (Nguyen 2013). The major features characterizing a micro-
componentormicro-productare:sizerangingfromfewmicrometersupto100µm,
tolerancesbetterthan1µm,complicated3Dstructure,excellentsurfacefinishwith
surfaceroughnesslesserthanhalfµmandfabricatedusingmultiplematerialssuch
as titanium alloys, ceramics, hard steels, etc. (Chang 2012). A number of fabrica-
tion techniques have been proposed to meet the aforementioned requirements and
massfabricatethemicro-components ormicro-products.Theproposedtechniques
arebasedontransfer,printing,assembly,etching,andlithography(Rai-Choudhury
1997;Madou2009).Thevariousfabricationtechniqueshavethepotentialitytofabri-
catemicro-sizedcomponentsusinginorganicaswellasorganicmaterialsandlending
themthedesiredcomplex3Dshapes.Themicromachiningtechniquesofferapromis-
ingapproachforbridgingthegapbetweenmacroandmicro/nanodomains(Cardoso
andDavim2012;Piljeketal.2014;Leondes2007).
Theuseofsinglemachiningprocesstomanufacturethemicro-componentshas
anumberoflimitationssuchaspotentialitytoproducethedesiredcomplexshapes
with the desired accuracy, capability to mass produce such components, and pre-
dictability(Luoetal.2005).Tominimizethelimitationsassociatedwiththestand-
alonesystems,machineswithmultifunctionalcapabilitieshavebeendevelopedthat
havethepotentialitytoimplementseveralmachiningmechanismsononemachine.
Themultifunctionalmachining mechanismaidsinrapidandeconomic fabrication
of micro-components. Integration of conventional and nonconventional microma-
chining process has been the focal point of the research community recently. The
integrationisoftenreferredtoashybridmicromachiningprocesses(El-Hofy2005).
Therecentapplicationsofhybridmicromachiningprocesseshavedemonstratedtheir
capabilitytoeffectivelymachinehard-to-machinematerialswithhighergeometrical
©TheAuthor(s),underexclusivelicensetoSpringerNatureSwitzerlandAG2019 1
S.BhowmikandD.Zindani,HybridMicro-MachiningProcesses,
SpringerBriefsinAppliedSciencesandTechnology,
https://doi.org/10.1007/978-3-030-13039-8_1
2 1 OverviewofHybridMicro-manufacturingProcesses
accuracy and surface integrity. The tool life has also been revealed to increase in
tandemwiththeefficiencyofthemachiningprocesses.
However,therehasbeennoexactdefinitiontoproperlydescribeahybridmachin-
ingprocess(Zhuetal.2013).Pastresearchershavegiventheirdefinitionsfromtime
to time (Rajurkar et al. 1999; Aspinwall et al. 2001; Curtis et al. 2009; Lauwers
2011). As for instance, Aspinwall et al. (2001) have described hybrid machining
processesasacombinationofmachiningprocessesthatareappliedindividuallyand
independentlyonasinglemachine.Theyhavealsodescribedthehybridprocesses
as assisted processes wherein two or more processes are applied simultaneously.
InanotherdefinitionproposedbySheandHung(2008),themachinescarryingout
differentoperationsatoneplaceareregardedashybridmachinesandtheprocesses
carriedoutbythemarereferredtoashybridmachiningprocesses.Anarrowerdef-
initionwasprovidedbyCurtisetal.(2009)whohavedescribedtheterm“hybrid”
asamachiningmethodwheretwoormorematerialremovalprocessesworksimul-
taneously. Following definition has been put forth by College International Pour
la Recherche en productique (CIRP): the interaction of various machining mech-
anisms/tools/energy sources simultaneously and in a controlled manner results in
hybrid machining processes. The simultaneous and controlled interaction signifies
thatthedifferentmechanismsofenergy/processesmustactinaparticularprocessing
zoneandatthesametime.Thehybridizationthereforecanhavesignificanteffecton
themachiningperformanceandtherelatedvariables.
1.2 ClassificationofHybridMicro-manufacturing
Processes
Thehybridmicromachiningprocessescanbeclassifiedonthebasisofthefollowing:
(cid:129) TypeI:Combinationoftwoormoreprocesseswhereinthematerialremovaltakes
placebecauseofthesimultaneousactionoftheprocessesinacontrolledmanner.
Theresultingmaterialremovalisthenetobtainedfromtheindividualprocesses.
(cid:129) Type II: Additional usage of energy sources aiding in the net material removal,
resultinginanenhancedmachiningperformance.
(cid:129) TypeIII:Usageoftoolsthatcansimultaneouslymachinetwoormoresurfaces.
Electro-discharge micro-grinding (EDG) is one of the examples for the Type I
category. In EDG process, material removal takes place as a combined effect of
electro-dischargephaseandduetoabrasionresultingfromgrinding.Thecombina-
tionresultsinimprovedflushingandhenceenhancedmaterialremovalrateincom-
parisontotheelectro-dischargemachining.Laser-assistedmicro-millingmachining
processfallsunderTypeIIcategorywhereinthematerialisheatedusinglaserenergy
whichaidsinenhancingthematerialremovalrateofthemillingprocess.Theenergy-
assistedhybridprocessescanbeusedforhard-to-machinematerials.Theprocesses
fallingunderTypeIIIcategoryensurethatthesinglepassmachiningissufficientfor
machiningtwoormoresurfacessimultaneously.Abriefdiscussionontheclassifi-
cationschemeensuesnext.