Material Behavior in Micro Milling of Zirconium Based Bulk Metallic Glass

Xie, Boyuan; Maroju, Naresh Kumar; Yan, David; Jin, Xianyu

doi:10.1007/978-3-319-51493-2_34

Cited by 8 publications

(8 citation statements)

References 15 publications

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“…Table 1 shows the summary of the research carried out on conventional machining of BMG, the challenges reported, and solutions offered. High feed rate and spindle speed produced light with extensive intensity due to heat accumulation [4].…”

Section: Grinding Of Metallic Glassmentioning

confidence: 99%

“…Greer and Ma (2007) [8] reported major challenges relating to material issues in BMG development, and how the structure-properties relationships of BMGs influence their applications. The authors [3], (b) milling [4], and (c) turning process [5]. (With kind permissions from Elsevier (a,c) and Springer (b)).…”

Section: Introductionmentioning

confidence: 99%

“…In addition, especially for conventional machining processes, metallic glass introduces challenges in reducing oxidization, tool life, and chip formation. One of the signature phenomena in the machining of BMGs is the light emission phenomenon and/or creation of lightning chips, which introduces a fire hazard during machining, as can be seen in Figure 1 [ 3 , 4 , 5 ]. The machining of metallic glasses is desirable in the manufacturing of electronic components, precision surgical instruments, and micro-electro-mechanical devices.…”

Section: Introductionmentioning

confidence: 99%

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Multi-Scale Traditional and Non-Traditional Machining of Bulk Metallic Glasses (BMGs)—Review of Challenges, Recent Advances, and Future Directions

Jahan,

Niraula,

Nafi

et al. 2024

Micromachines

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Bulk metallic glasses (BMGs) are growing in popularity prominently due to their potential in micro-electromechanical systems (MEMSs) and aerospace applications. BMGs have unique mechanical properties, i.e., high strength, hardness, modulus of elasticity, and wear resistance, due to their disordered atomic structure. Due to their unique mechanical properties and amorphous structures, machining of BMGs remains a challenge. This paper aims to carry out a detailed literature review on various aspects of the machining of bulk metallic glasses using both conventional and non-conventional processes, including experimental approaches, modeling, statistical findings, challenges, and guidelines for machining this difficult-to-machine material. Conventional machining processes were found to be challenging for machining bulk metallic glasses due to their high hardness, brittleness, and tendency to convert their amorphous structure into a crystalline structure, especially at the machined surface and sub-surface. Although their high electrical conductivity makes them suitable for machining by non-conventional processes, they impose new challenges such as heat-affected zones and crystallization. Therefore, the successful machining of BMGs requires more in-depth analysis of cutting forces, tool wear, burr formation, surface finish, recast layers or heat-affected zones, crystallization, and mechanical property changes among different varieties of BMGs. This review paper provides guidelines emerging from in-depth analysis of previous studies, as well as offering directions for future research in the machining of BMGs.

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Section: Grinding Of Metallic Glassmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Multi-Scale Traditional and Non-Traditional Machining of Bulk Metallic Glasses (BMGs)—Review of Challenges, Recent Advances, and Future Directions

Jahan,

Niraula,

Nafi

et al. 2024

Micromachines

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show abstract

“…Xie et al employed micro-milling techniques for processing BMGs. The research findings indicate that, with appropriate mechanical machining methods, achieving ideal geometric precision and surface quality on BMGs' components is feasible [5]. Chen et al utilized electrical discharge machining techniques to process BMGs.…”

Section: Introductionmentioning

confidence: 99%

An Investigation in Sub-Millimeter Channel Fabrication by the Non-Aqueous Electrolyte Jet Machining of Zr-Based Bulk Metallic Glasses

Guo,

Zhou,

et al. 2023

Micromachines

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Zr-based bulk metallic glasses (BMGs) have many unique properties. Due to their excellent performance and manufacturing process, they have become a research focus in the material science community. Electrolyte Jet Machining (EJM) is a non-contact electrochemical processing method with high surface integrity and high material removal rate (MRR). In this research, the sub-millimeter channels fabricated by EJM on Zr-based BMGs have been studied to explore the dissolution mechanisms and surface integrity under different scanning rates and voltages. The results show that, with other machining parameters holding constant, an increase in voltage leads to a substantial enhancement in both the depth and width of the channels machined on Zr-based BMGs. Notably, the influence of voltage on the depth of the channels is particularly pronounced. Additionally, an escalation in scanning rate correlates with a decrease in channel depth, with minimal variation in channel width. This study indicates that alcohol-based EJM is an effective method to fabricate sub-millimeter channels and modulate structures on Zr-based BMGs.

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“…But these cannot be presently integrated together due to fabrication incompatibilities. Previous work has been done on bulk micromachining of metal mesoscale structures [17,26,[28][29][30][31][32][33], and this work has shown micromilling to be an accurate and effective method of creating lm to cm scale structures. Surface micromachined electrical structures have also been demonstrated [27,34,35]; however, these two types of structures have not generally been integrated due to interfaces incompatibilities.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Six Degrees-of-Freedom Hexflex Positioner With Integrated Strain Sensing Using Nonlithographically Based Microfabrication

Panas

Culpepper

2021

Journal of Micro and Nano-Manufacturing

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A process flow is described for the low cost, flexible fabrication of metal MEMS with high performance integrated sensing. The process is capable of producing new designs in ≈ 1 week at an average unit cost of <$1k/device even at batch sizes of ≈ 1-10, with expected sensing performance limits of about 135dB over a 10khz sensor bandwidth. This is a ≈20x reduction in cost, ≈25x reduction in time, and potentially >30x increase in sensing dynamic range over comparable state-of-the-art compliant nanopositioners. The Non-Lithographically Based Microfabriction (NLBM) process is uniquely suited to create high performance nanopositioning architectures which are customizable to the positioning requirements of a range of nanoscale applications. These can significantly reduce the cost of nanomanufacturing research and development, as well as accelerate the development of new processes and the testing of fabrication process chains without excess capital investment. A 6-DOF flexural nanopositioner with integrated sensing for all 6-DOF was fabricated using the newly developed process chain. The fabrication process was measured to have ≈30µm alignment. Sensor arm, flexure, and trace widths of 150µm, 150µm and 800µm, respectively, were demonstrated. Process capabilities suggest lower bounds of 25 µm, 50µm and 100µm, respectively. Dynamic range sensing of 52dB was demonstrated for the nanopositioner over a 10kHz sensor bandwidth. Improvements are proposed to approach sensor performance of 132dB over a 10kHz sensor bandwidth.

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Material Behavior in Micro Milling of Zirconium Based Bulk Metallic Glass

Cited by 8 publications

References 15 publications

Multi-Scale Traditional and Non-Traditional Machining of Bulk Metallic Glasses (BMGs)—Review of Challenges, Recent Advances, and Future Directions

Multi-Scale Traditional and Non-Traditional Machining of Bulk Metallic Glasses (BMGs)—Review of Challenges, Recent Advances, and Future Directions

An Investigation in Sub-Millimeter Channel Fabrication by the Non-Aqueous Electrolyte Jet Machining of Zr-Based Bulk Metallic Glasses

Fabrication of Six Degrees-of-Freedom Hexflex Positioner With Integrated Strain Sensing Using Nonlithographically Based Microfabrication

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