1. Department of Mechanical Engineering IITD
Industry Day Theme # 2 : Smart Manufacturing
Advanced CNC Micromachining System with Integrated Micro-tool Manufacturing
Harish Kumar, Jitin Malhotra, Ashish Kumar Sahu, Hardik A. Patel, Sunil Jha*
Abstract
Emerging miniaturization technologies are driving developments in microscale processes, machines and metrology to meet needs related to part sizes, feature definition, accuracy & precision, and materials development. Highly precise and accurate micro components with size ranging from few hundred microns to few millimeters and features ranging in few hundred microns are in high demand for industries such as automotive, electro-optics, aerospace, biotechnology, information technology etc.
Result
Introduction
The Advanced CNC Micromachining System aims to develop a multifunction micro-machining system capable of micro-Milling, micro-Drilling, micro-Grinding, micro-Electric Discharge Machining (EDM), micro-Laser Beam Machining (LBM) and in-situ metrology in a single setup. This multifunction system enables to fabricate different micro components using different materials with optimal parameters using conventional as well as unconventional machining methods. The single settings attain the repeatability which is critical in dealing with the meso/micro components.
Materials and Methods
µ-LBM on Ti6Al4V
µ-Grinding on Polycarbonate
µ-Milling on Ti6Al4V
µ-EDM on Ti6Al4V by Brass and Copper electrode
Figure 2: Advanced Micromachining center Under Development
µ-Grinding Tool Manufacturing
µ-EDM Electrically Isolated Tool
Department of Mechanical Engineering IITD
High Speed µ-Milling Spindle
µ-LBM
Figure1: µ-EDM Drilling Experiments on Ti6Al4V
Conclusions
AMMS is a combination of conventional and non-conventional processes in a single CNC machining setup to overcome the constraints of individual micromachining techniques for precise manufacturing of 3D geometries.
In-situ measurement of geometrical parameters, surface roughness and forces to overcome repositioning error while measurement.
Figure 3: Micromachine Performance with different tools
References
Tanaka M (2001) Development of desktop machining microfactory. Riken Rev 34:46–49.
Kussul E, Baidyk T, Ruiz-Huerta L, Caballero-Ruiz A, Velasco G, Kasatkina L (2002) Development of micro machine tool prototypes for microfactories. J Micromech Microeng 12(6):795–812.
Bang YB, Lee KM, Oh S (2005) 5-Axis micro milling machine for machining micro parts. Int J Adv Manuf Technol 25:888–894.
Li H, Lai X, Li C, Lin Z, Miao J, Ni J (2008) Development of meso-scale milling machine tool and its performance analysis. Front Mech Eng China 3(1):59–65.
Acknowledgement
The AMMS machine has been fabricated at the Department of Mechanical Engineering, Indian Institute of Technology Delhi, India under the Technology Systems Development (TSD) program funded by the Department of Science and Technology (DST) Government of India.
Industrial Significance
Automotive, Aerospace, MEMS, Bio Medical, Jewellery and Research development
Technology Readiness Level: AMMS has been design and developed and under testing phase.