Investigation on Hybrid Mechano-electrochemical Milling of Ti6Al4V

Camp, Dries Van; Bouquet, Jan; Qian, Jun; Zhang, Fei; Lauwers, Bert

doi:10.1016/j.procir.2017.12.158

Cited by 24 publications

(18 citation statements)

References 6 publications

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“…Complex structures had been fabricated on PCB earlier, by many methods such as chemical etching, 21 photolithography, 22,23 silkscreen 24 and micro-milling. 25–27 Historically, the first etchant that was used in the manufacturing of PCBs was ferric chloride (FeCl 3 ) and it is still used for small-scale production systems. 28 When the dimensions of the tracks to be etched are small, there is a strong need for precision processes 29,30 and processes that yield better surface finish 31 with an overall high yield.…”

Section: Methodsmentioning

confidence: 99%

Fabrication of micro-mixer on printed circuit board using electrochemical micromachining

Singh

Bhattacharya

2019

Journal of Micromanufacturing

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Electrochemical micromachining (ECMM) has been mostly carried out in situations demanding precision, complexity in the shapes of final components and in case the surface integrity and performance are independent of the machining process. In this work, the following have been demonstrated: The first part of the work demonstrates the experimental setup for ECMM that is used to fabricate a micro-mixer on a printed circuit board (PCB) substrate by using a single point electrochemical machining tool with a tip diameter—150 µm. The method is able to show a promising route of fabrication where the circuit lines on a PCB substrate can be printed with high yield and processing speeds. The second part of the article points out that machining can be carried out on PCB substrates through electrochemical processes using a single point tool and a minimum feature size of 243 µm can be machined with a fine tolerance of 0.025 µm and roughness = 3.0459 µm~7.2404 µm. The third part of the article reports the geometrical parameters of a relatively complex geometry of a micro-mixer which is arrived at through a COMSOL based simulation platform that is fabricated using the mentioned manufacturing process. The process is further validated through the design of experiments, and fluid flow and mixing behaviour on the fabricated structure is evaluated through an epifluorescence microscope. The advantages that this technique may offer is in terms of achieving an overall low feature size in comparison to micro-milling and avoiding the complexities of lithography-driven processes to produce a process which has a much lower equipment dependency, is environmentally benign in comparison to the lithography driven techniques and is overall low in cost.

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Section: Methodsmentioning

confidence: 99%

Fabrication of micro-mixer on printed circuit board using electrochemical micromachining

Singh

Bhattacharya

2019

Journal of Micromanufacturing

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“…The critical aspect in this hybrid technology is the design of a tool which is compatible with both milling and electrochemical machining. This is accomplished by using a cutting edge in the ECM tool [221]. Since, the cutting edge is always in contact with workpiece surface, it should be made of a material with very low electrical conductivity so as to avoid short-circuits which are not favorable for ECM process.…”

Section: (B) Mechano-electrochemical Milling (Mecm)mentioning

confidence: 99%

“…Figure 28 two zones can be distinguished clearly. Zone 1 corresponds to mechanical cutting action by cutting edge whereas Zone 2 represents ECMed surface [221]. The cutting edge is primarily responsible for removal of passivating layer during electrochemical machining of Titanium.…”

Section: (B) Mechano-electrochemical Milling (Mecm)mentioning

confidence: 99%

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A review on process capabilities of electrochemical micromachining and its hybrid variants

Saxena

Qian

Reynaerts

2018

International Journal of Machine Tools and Manufacture

167

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Electrochemical micromachining (micro-ECM) is an unconventional micromachining technology that has capability to fabricate high aspect ratio micro-holes, micro-cavities, microchannels and grooves on conductive and difficult-to-cut materials. Both academia and industry have the consensus that it offers promising machining performance especially in terms of high surface finish, no tool wear and absence of thermally induced defects. Furthermore in order to machine novel materials with extreme properties, novel hybrid electrochemical micromachining technologies are under development. With these hybrid micro-ECM technologies, capabilities of micro-ECM can be expanded by combining it with other processes. To fully exploit the potential as well as improve micro-ECM technology and related hybrid processes, a wide spectrum of multidisciplinary knowledge is needed. The present review systematically discusses process capabilities and research developments of electrochemical micromachining and its hybrid variants considering knowledge of both basic and applied research fields. After few introductory review articles in prior state of the art, this review fills an important gap in research literature by presenting first time an extended literature source with a wide coverage of recent research developments in electrochemical micromachining technology and its hybrid variants. This paper outlines the research and engineering developments in electrochemical micromachining technology and its hybrid variants, review of the related concepts, aspects of tooling, advanced process capabilities and process energy sources. It also provides new sights into technological understanding of micro-ECM technology which will be helpful in future engineering developments of this technology.

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“…However, structure functionalities are limited because only a single, or a few, materials are used. Many studies have sought to create complex, multi-material, full 3D structures [6,7]. MEMS/NEMS fabrication processes that do not exhibit unexpected chemical reactions during masking and etching, and hybrid processes (the use of two or more processes simultaneously or sequentially) have been explored.…”

Section: Introductionmentioning

confidence: 99%

50 nm Scale Alignment Method for Hybrid Manufacturing Processes for Full 3D Structuring

Jang

Yoon

Lee

et al. 2020

Int. J. Precis. Eng. Manuf.

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In micro-/nano-scale, multi-material three-dimensional (3D), structuring has been a major research area for making various applications. To overcome dimensional and material limitations, several hybrid processes have been proposed. The hybrid processes were performed in the same or different numerically controlled stages. If the stages differed, the substrate was moved and locked to the stage before fabrication. During the locking, alignment error occurred. This error became problematic because this significantly compromised the quality of final structures. Here, an alignment method for a hybrid process consisted of a focused ion beam milling, aerodynamically focused nanoparticle printing, and micro-machining was developed. Two sets of collinear marks were placed at the edges of the substrate. Rotational and translational errors were calculated and compensated using the marks. Processes having different scales were bridged through this alignment method. Various materials were utilized, and accuracy was less than 50 nm when the length of the substrate was less than 13 mm. The alignment method was employed to fabricate a V-shaped structure and step-shaped structure using polymer, ceramic, and metal.

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Investigation on Hybrid Mechano-electrochemical Milling of Ti6Al4V

Cited by 24 publications

References 6 publications

Fabrication of micro-mixer on printed circuit board using electrochemical micromachining

Fabrication of micro-mixer on printed circuit board using electrochemical micromachining

A review on process capabilities of electrochemical micromachining and its hybrid variants

50 nm Scale Alignment Method for Hybrid Manufacturing Processes for Full 3D Structuring

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