Masked micro-channel machining in aluminum alloy and borosilicate glass using abrasive water jet micro-machining

Haghbin, Naser; Ahmadzadeh, Farbod; Papini, M.

doi:10.1016/j.jmapro.2018.08.017

Cited by 30 publications

(5 citation statements)

References 37 publications

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“…Results of machining certain features like channels using AWJM could differ when a mask is used to conduct the process. Haghbin et al [56] conducted a study on machining microchannels in aluminum alloy and borosilicate glass with and without a mask and compared the results. It was found that utilizing a mask influenced the shape, depth, and surface quality of the machined channels.…”

Section: Unmasked and Masked Micro-millingmentioning

confidence: 99%

Controlled Depth Micro-Milling of Aluminum Oxide Using Abrasive Waterjet Machining to Create Micro-Molds with Free-Standing structures

Ibrahim

2024

Preprint

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Abrasive waterjet machining has gained popularity due to the many advantages it possesses over conventional machining systems. These include the high achievable tolerance as well as minimal tool wear since it is a non-contact machining method. Previous studies utilized stainless steel masks cut using abrasive waterjet micro-machining (AWJM) together with abrasive slurry jet micro-machining (ASJM) to mill micro-molds in Al6061-T6 for the casting of polymeric microfluidic chips with intersecting micro-channels. However, the deflection of the slurry jet from the mask edge was found to lead to two undesirable effects: a trench along the edges of the raised structures representing the channels, and an undercut of the mask. Both effects were linked to the propensity of ductile materials to erode more rapidly at oblique incidence rather than perpendicular incidence. This thesis investigates the hypothesis that these effects can be greatly reduced by using AWJM to machine the molds into more brittle materials which erode in the opposite fashion, i.e., more rapidly at perpendicular than oblique incidence. To demonstrate this, AWJM was used to machine masks from aluminum oxide and subsequently mill micro-molds with raised intersecting free-standing structures into aluminum oxide substrates. By controlling the process parameters, it was found that for molds of identical depth, the undercut was reduced by five times and the undesirable erosion was reduced by about four-fold when compared to molds machined in Al6061 using the AWJM/ASJM hybrid technique. It was also found that much deeper molds could be made in aluminum oxide, with intersecting raised free-standing structures of up to 435 μm in height while still maintaining an acceptable surface quality, undercut, and undesirable erosion. Finally, since the technique involved only AWJM, it was much more convenient than the previously utilized hybrid AWJM/ASJM.

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Section: Unmasked and Masked Micro-millingmentioning

confidence: 99%

Controlled Depth Micro-Milling of Aluminum Oxide Using Abrasive Waterjet Machining to Create Micro-Molds with Free-Standing structures

Ibrahim

2024

Preprint

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“…The most extensively studied use of abrasive-H 2 O-jet technology is in the manufacturing of aluminium alloys. Range of Al alloys investigated in scientific studies is very wide, ranging from approximately unadulterated aluminium alloys (1xxx series) [11,12] to Al-Mg alloys (5xxx series) [11,13,14], Al-Mg-Si alloys (6xxx series) [11,[15][16][17][18][19][20][21][22], and Al-Zn-Mg alloys (7xxx series) [11,23,24]. Table 1.…”

Section: Design Of Experiment-doementioning

confidence: 99%

Experiment of Input Parameters on Abrasive Water Jet Machining

Rai¹,

Jha²

2021

JUSST

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This analysis looks at the impact of modifying the coarse water jet wounding limitations on the disorder of the work piece’s superficial layer. Air Jet for Abrasiveness The aerospace industry mostly uses machining to remove high-métier components and additional composites. The majority of his uses are in the machining of a gas turbines, engines, spacecraft, atomic reactors, and pumps, among other things. Rough waterjet machining is a new machining technique in which materials a is removed by abrasion. A high-velocity watercourse of abrasive subdivisions combined through purified water is directed at the work superficial. The current research focuses on the experimental investigation and assessment of abrasive H2O jet machining procedure using reaction surface technique to assess the technical factors influencing the machining efficiency of CFRP laminate. Kerf candle, delamination, material elimination rate, and superficial roughness were found to be affected by standoff coldness, feedstuff rate, and jet strain. The material connected parameter, location of fiber, has been also found to touch the machining performance. Using Taguchi’s principle, Design of Experimentations are used to determine the impact of process strictures on optimal environment. To determine the best conditions, a series of tests are carried out. Method parameter optimization is expected. To verify the desired degree of Processes parameter prediction, a conformation experiment is carried out.

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“…AWJM utilizes high-pressure water passing through a small orifice in order to entrain dry abrasive particles and air. The resulting mixture passes through a micro-sized mixing tube at high speed, and can be used to perform controlled-depth micro-machining [27,87,88] on virtually any material. High-pressure ASJM entrains a slurry rather than dry abrasive, thus eliminating the effect of entrained air into the mixing tube, resulting in improved surface finish, although at the penalty of a reduced material removal rate [1].…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

Azarsa¹

2023

Preprint

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Many advanced engineering materials are machined using abrasive water jets, a non-traditional machining method that has certain advantages compared to other approaches. This dissertation aims at developing methodologies to use abrasive water and slurry jets to micro-machine free-standing structures for heat sink and microfluidics applications. The first aim was to fabricate high aspect ratio free-standing structures with a minimum distance between each other that would lead to maximum heat transfer performance in heat sinks. The effect of machining process parameters on the quality of the resulting free-standing structures was studied. It was demonstrated that high-quality free-standing structures with aspect ratios of more than 40 to be used as fins in heat sinks could be fabricated. There is an increasing demand for metallic micro-molds that can be used for inexpensive mass production of polymeric microfluidic chips. Therefore, the feasibility of using abrasive water jet micro-machining (AWJM) and abrasive slurry jet micro-machining (ASJM) to fabricate such micro-molds was studied. Jet raster scans under various combinations of process parameters were used in order to machine micro-pockets containing free-standing structures, representing molds for casting microfluidic chips with channel networks. The optimum process parameters and material were determined in order to fabricate the molds with the best possible surface finish. Because unmasked machining could not be used to fabricate molds with sharp-edged intersecting features, a hybrid AWJM/ASJM masked machining technique was introduced. By careful selection of the process parameters, high quality molds with both single and intersecting free-standing structures at multiple heights could be fabricated, thus making three-dimensional microfluidic chip mold fabrication feasible. Finally, a new method of mold fabrication that utilized water jet cutting technology to cut free-standing structures out of mild steel sheets, to be used as a mold for PDMS casting, was developed. This enabled 3D features having very abrupt changes in depth with almost 90o angles for use in microfluidic devices. As a proof-of-concept, a polydimethylsiloxane (PDMS) chip was made and tested. It was shown that this alternative approach to create microfluidic molds is versatile and may find utility in reducing the cost and complexity involved in fabricating 3D features in microfluidic devices.

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Masked micro-channel machining in aluminum alloy and borosilicate glass using abrasive water jet micro-machining

Cited by 30 publications

References 37 publications

Controlled Depth Micro-Milling of Aluminum Oxide Using Abrasive Waterjet Machining to Create Micro-Molds with Free-Standing structures

Controlled Depth Micro-Milling of Aluminum Oxide Using Abrasive Waterjet Machining to Create Micro-Molds with Free-Standing structures

Experiment of Input Parameters on Abrasive Water Jet Machining

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

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