No abstract

The concept of smart manufacturing has become an important issue in the manufacturing industry since the start of the twenty-first century in terms of time and production cost. In addition to high production quality, a quick response could determine the success or failure of many companies and factories. One the most effective concepts for achieving a smart manufacturing industry is the use of computer-aided process planning (CAPP) techniques. Computer-aided process planning refers to key technology that connects the computer-aided design (CAD) and the computer-aided manufacturing (CAM) processes. Researchers have used many approaches as an interface between CAD and CAPP systems. In this field of research, a lot of effort has been spent to take CAPP systems to the next level in the form of automatic computer-aided process planning (ACAPP). This is to provide complete information about the product, in a way that is automated, fast, and accurate. Moreover, automatic feature recognition (AFR) techniques are considered one of the most important tasks to create an ACAPP system. This article presents a comprehensive survey about two main aspects: the degree of automation in each required input and expected output of computer-aided process planning systems as well as the benefits and the limitations of the different automatic feature recognition techniques. The aim is to demonstrate the missing aspects in smart ACAPP generation, the limitations of current systems in recognising new features, and justifying the process of selection.

Electrochemical machining is a relatively new technique, only being introduced as a commercial technique within the last 70 years. A lot of research was conducted in the 1960s and 1970s, but research on electrical discharge machining around the same time slowed electrochemical machining research. The main influence for the development of electrochemical machining came from the aerospace industry where very hard alloys were required to be machined without leaving a defective layer in order to produce a component which would behave reliably. Electrochemical machining was primarily used for the production of gas turbine blades or to machine materials into complex shapes that would be difficult to machine using conventional machining methods. Tool wear is high and the metal removal rate is slow when machining hard materials with conventional machining methods such as milling. This increases the cost of the machining process overall and this method creates a defective layer on the machined surface. Whereas with electrochemical machining there is virtually no tool wear even when machining hard materials and it does not leave a defective layer on the machined surface. This article reviews the application of electrochemical machining with regards to micro manufacturing and the present state of the art micro electrochemical machining considering different machined materials, electrolytes and conditions used.

No abstract

This paper is based on the information gathered within the Multi-Material Micro-Manufacture (4M) Network activities in the Processing of Metals Division (Task 7.2 ‘Tooling’) ( www.4m-net.org ). The aim of the task involves a systematic analysis of the partners' expertise in different microtechnologies for processing tooling inserts made of metal. The following technologies have been analysed: micromilling, micro-electrodischarge machining (EDM, including wire-EDM, sinking-EDM, and EDM-milling), laser micromachining, electroforming, and electrochemical milling (ECF) (an electrochemical machining innovative process proposed by HSG-IMAT). Considered tool-insert materials are nickel for electroforming, stainless steel for ECF, and tool steel (AISI H13) for all other processes. Typical features (ribs, channels, pins, and holes) required by micro-optics, microfluidics, and sensor and actuator applications have been selected to form the benchmark part and to carry out this analysis. The results provide a global comparison between the micromanufacturing processes mentioned earlier in terms of technical capabilities and cost effectiveness of different feature machinings. As a second result, the current limitations of these technologies concerning feature sizes, surface finish, aspect ratios, etc. have been identified. The main conclusion drawn is the absence of a consolidated technology to produce three-dimensional free-form shapes smaller than 100–200 μm to date.

No abstract

No abstract

Electrochemical machining is a non-conventional machining technique used across a large range of industries from aero to medical. A large number of papers exist on the topic of electrochemical machining (ECM) and electrochemical micromachining (ECMM) which is a daunting task to evaluate for anyone new to the subject. This paper aims to summarise some of the major parameters used in electrochemical machining which affect machining accuracy, machining rate and the suitability of the process for micromachining. This paper does not propose to be in any way complete but a starting point for anyone new to the subject of electrochemical machining. This paper aims to find new areas to study within the electrochemical micro-machining field.