Micro tool design and fabrication: A review

Oliaei, Samad Nadimi Bavil; Karpat, Yiğit; Davim, J. Paulo; Perveen, Asma

doi:10.1016/j.jmapro.2018.10.038

Cited by 58 publications

(23 citation statements)

References 152 publications

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“…Many protective coatings against wear and corrosion which may be applied for cutting tools are not considered here due to the huge variety of their types and infinite number of specific tasks; however, some general principles and tendencies were discussed, while more information is available in specialised papers and reviews [7,155,[207][208][209][210][211]. Although chemical vapour deposition and physical vapour deposition are the two main methods of protective coating fabrication, it is suggested to look deeply into thematic papers and reviews to learn about different techniques [212,213] or find details on deposition methods in research papers concerned with specific materials and structures.…”

Section: Thermal Barrier Coatingsmentioning

confidence: 99%

The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

et al. 2020

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A variety of cutting tool materials are used for the contact mode mechanical machining of components under extreme conditions of stress, temperature and/or corrosion, including operations such as drilling, milling turning and so on. These demanding conditions impose a seriously high strain rate (an order of magnitude higher than forming), and this limits the useful life of cutting tools, especially single-point cutting tools. Tungsten carbide is the most popularly used cutting tool material, and unfortunately its main ingredients of W and Co are at high risk in terms of material supply and are listed among critical raw materials (CRMs) for EU, for which sustainable use should be addressed. This paper highlights the evolution and the trend of use of CRMs) in cutting tools for mechanical machining through a timely review. The focus of this review and its motivation was driven by the four following themes: (i) the discussion of newly emerging hybrid machining processes offering performance enhancements and longevity in terms of tool life (laser and cryogenic incorporation); (ii) the development and synthesis of new CRM substitutes to minimise the use of tungsten; (iii) the improvement of the recycling of worn tools; and (iv) the accelerated use of modelling and simulation to design long-lasting tools in the Industry-4.0 framework, circular economy and cyber secure manufacturing. It may be noted that the scope of this paper is not to represent a completely exhaustive document concerning cutting tools for mechanical processing, but to raise awareness and pave the way for innovative thinking on the use of critical materials in mechanical processing tools with the aim of developing smart, timely control strategies and mitigation measures to suppress the use of CRMs.

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Section: Thermal Barrier Coatingsmentioning

confidence: 99%

The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

et al. 2020

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“…In particular, microtools with complex inner structures, e.g., extrusion dies, are difficult to manufacture because close tolerance and good surface quality are simultaneously required. [ 42 ] At present, conventional precision machining just satisfies the demands of tool features larger than several tens of micrometers. [ 16 ] The combination of precision machining and a high‐energy‐beam process can overcome these difficulties in micro‐die fabrication with a minimum feature size at sub‐10 µm and good surface roughness at the nanoscale.…”

Section: Basic Variants Of Micro/nanoformingmentioning

confidence: 99%

“…[ 16 ] The combination of precision machining and a high‐energy‐beam process can overcome these difficulties in micro‐die fabrication with a minimum feature size at sub‐10 µm and good surface roughness at the nanoscale. [ 42,43 ] In addition, flexible microtools using soft material such as rubber material, which can eliminate alignment difficulties during assembly, are also another important future development of micro/nanoforming to fabricate high‐quality microparts with complex shapes at a low cost. [ 44,45 ] Finally, many problems that occur in micro/nanoforming processes are associated with machines in miniaturization.…”

Section: Basic Variants Of Micro/nanoformingmentioning

confidence: 99%

A Review on Micro/Nanoforming to Fabricate 3D Metallic Structures

Wang

et al. 2020

Advanced Materials

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With the rapid development of micro‐electromechanical systems (MEMS), micro/nanoscale fabrication of 3D metallic structures with complex structures and multifunctions is becoming more and more important due to the recent trend of product miniaturization. As a promising micromanufacturing approach based on plastic deformation, micro/nanoforming shows the attractive advantages of high productivity, low cost, near‐net‐shape, and excellent mechanical properties, compared with other non‐silicon‐based micromanufacturing technologies. However, micro/nanoforming is far less established due to the so‐called size effects in terms of materials models, process laws, tooling design, etc. The understanding of basic issues on micro/nanoforming is not yet mature, and it is currently a topic of rigorous investigation. Here, a systematic review on the micro/nanoforming processes of 3D structures with multifunctional properties is presented, wherein also a critical examination of the interplay between relevant length scales and size effects affecting the structural integrity of micro/mesoscale metallic systems is also provided. Finally, the challenges of micro/nanoscale fabrication are proposed, including the development trends of new micro/nanoforming processes, multiple field coupling effects, and theoretical modeling at the trans‐scale.

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“…It is well known that electrode miniaturization is critical for μEDM because it determines the precision of the process to manufacture smaller and more precise parts [ 4 ]. Many methods have been proposed for fabricating microelectrodes.…”

Section: Introductionmentioning

confidence: 99%

Investigation of a Liquid-Phase Electrode for Micro-Electro-Discharge Machining

Huang

Zhu

et al. 2020

Micromachines

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Micro-electro-discharge machining (μEDM) plays a significant role in miniaturization. Complex electrode manufacturing and a high wear ratio are bottlenecks for μEDM and seriously restrict the manufacturing of microcomponents. To solve the electrode problems in traditional EDM, a µEDM method using liquid metal as the machining electrode was developed. Briefly, a liquid-metal tip was suspended at the end of a capillary nozzle and used as the discharge electrode for sparking the workpiece and removing workpiece material. During discharge, the liquid electrode was continuously supplied to the nozzle to eliminate the effects of liquid consumption on the erosion process. The forming process of a liquid-metal electrode tip and the influence of an applied external pressure and electric field on the electrode shape were theoretically analyzed. The effects of external pressure and electric field on the material removal rate (MRR), liquid-metal consumption rate (LMCR), and groove width were experimentally analyzed. Simulation results showed that the external pressure and electric field had a large influence on the electrode shape. Experimental results showed that the geometry and shape of the liquid-metal electrode could be controlled and constrained; furthermore, liquid consumption could be well compensated, which was very suitable for µEDM.

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Micro tool design and fabrication: A review

Cited by 58 publications

References 152 publications

The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

A Review on Micro/Nanoforming to Fabricate 3D Metallic Structures

Investigation of a Liquid-Phase Electrode for Micro-Electro-Discharge Machining

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