Development of a novel custom micro-tool for effective cutting of a precision microgroove array on a microscope slide

Chen, Shun Tong; Lai, Yun Cheng

doi:10.1088/0960-1317/21/3/035020

Cited by 5 publications

(3 citation statements)

References 15 publications

(15 reference statements)

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“…A miniature w-EDM mechanism equipped with a completed control system for wire tension (brass wire of 50 µm diameter used) and wire vibration inhibition is designed and employed to support the micro w-EDM experiment as shown in figure 5(b). The mechanism is mounted in a work tank based on a previously designed tabletop CNC (computer numerical control) machine tool (Chen and Lai 2011). Based on the principle of magnetic levitation, a pair of small magnets are placed opposite each other at a distance d on the end of the delivery wire bobbin to resist the recovery wire bobbin's rotation thus the tension of the cutting wire is kept stable when leading out.…”

Section: Experimental Hardware Designmentioning

confidence: 99%

A novel power source for high-precision, highly efficient micro w-EDM

Chen

2015

J. Micromech. Microeng.

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The study presents the development of a novel power source for high-precision, highly efficient machining of micropart microstructures using micro wire electrical discharge machining (w-EDM). A novel power source based on a pluri resistance–capacitance (pRC) circuit that can generate a high-frequency, high-peak current with a short pulse train is proposed and designed to enhance the performance of micro w-EDM processes. Switching between transistors is precisely controlled in the designed power source to create a high-frequency short-pulse train current. Various microslot cutting tests in both aluminum and copper alloys are conducted. Experimental results demonstrate that the pRC power source creates instant spark erosion resulting in markedly less material for removal, diminishing discharge crater size, and consequently an improved surface finish. A new evaluation approach for spark erosion ability (SEA) to assess the merits of micro EDM power sources is also proposed. In addition to increasing the speed of micro w-EDM by increasing wire feed rates by 1.6 times the original feed rate, the power source is more appropriate for machining micropart microstructures since there is less thermal breaking. Satisfactory cutting of an elaborate miniature hook-shaped structure and a high-aspect ratio microstructure with a squared-pillar array also reveal that the developed pRC power source is effective, and should be very useful in the manufacture of intricate microparts.

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Section: Experimental Hardware Designmentioning

confidence: 99%

A novel power source for high-precision, highly efficient micro w-EDM

Chen

2015

J. Micromech. Microeng.

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“…Moreover, some methods have extremely low material removal rates or fail to produce microstructures with low surface roughness. Directly generating microgroove arrays using a custom-made micro diamond wheel-tool array seems to be a feasible approach [3]; Relating to the end milling-cutter-shaped grinding wheel fabrication by combining a compound electroplating approach with diamond abrasive had been investigated [4]. However, cutting at high temperatures triggers chemical wear (oxidation, dissolution, graphitization or carbide formation) of the diamond grinding edges.…”

Section: Introductionmentioning

confidence: 99%

Development of a Thin CBN Grinding-Tool by Compound Process

Chen¹,

Lai²

2013

AMM

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This study presents a compound process combining composite electroforming with wire Electrical Discharge Machining (w-EDM) for developing a thin cubic boron nitride (CBN) grinding-tool. A precisely designed set-up in which a small compound depositing tank providing effectual convection of a compound electroplating solution to help fabricate a CBN grinding-blank is presented. A funneled entrance design for converging CBN grits in the working tank and creating a depositing effect on the substrate is employed and proposed. Considerable micro CBN abrasives are evenly embedded into the nickel-based coating layer, which offers enough abrasives for grinding-edge. Subsequently, the coated grinding-blank is trued and dressed by using w-EDM to form a multiple thin CBN grinding-tool. Experimental results indicate that the electroforming process can create a Ni-based CBN layer of high-integrity under current density of 2 ASD and concentration of 8.6 g/l CBN grits. Moreover, the CBN grinding-edge of 10 μm in thickness (each edge) can be achieved.

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“…In this process, it is almost impossible to maintain uniform dispersal of diamond grains for a grinding edge of less than 10 µm thickness. Moreover, when a wheel tool has an extremely thin cutting edge, exceedingly high co-axial accuracy must be maintained to cut an accurate microgroove [3]. This study, therefore, examines the use of use of boron doping to create a PCD wheel-blank for thinning by micro rotary w-EDM approach.…”

Section: Introductionmentioning

confidence: 99%

Study on Thinning of a Boron-Doped Polycrystalline Diamond Wheel-Tool by Micro Rotary W-EDM Approach

Chen

Chang

2012

AMM

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This study presents a novel approach for using a micro rotary wire Electrical Discharge Machining (micro w-EDM) to thin the grinding-edge of a wheel-tool made from boron-doped polycrystalline composite diamond (PCD). For thinning the PCD, two discharge circuits (a Resistance-Capacitance (RC) circuit and a transistor) were used as power sources to obtain a grinding-edge of less than 10 µm in thickness and high surface quality. The wheel-blank is vertically mounted on a spindle and while rotating is thinned by micro w-EDM along a planned computer numerically controlled path. Experimental results verify that boron-doped PCD can be successfully thinned down to 5 µm in edge-thickness. The study shows it is possible to break (cut) diamonds of 10-µm grain size, leaving smooth surface-exposed diamonds at the cutting edge of the wheel tool. The dimensional and geometrical accuracy of the wheel-tool can be exactly controlled. Raman analysis reveals graphitizing of the PCD caused by local high temperature spark erosion at a peak of 1593 cm-1 in RC discharge circuit machining. The peak at 1332 cm-1 for the transistor circuit method indicates diamond sp3 structure. The surface degenerating layer produced by transistor circuit machining gives a suitably thin grinding edge with exposed diamond grains.

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Development of a novel custom micro-tool for effective cutting of a precision microgroove array on a microscope slide

Cited by 5 publications

References 15 publications

A novel power source for high-precision, highly efficient micro w-EDM

A novel power source for high-precision, highly efficient micro w-EDM

Development of a Thin CBN Grinding-Tool by Compound Process

Study on Thinning of a Boron-Doped Polycrystalline Diamond Wheel-Tool by Micro Rotary W-EDM Approach

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