Micromachining: An overview (Part I)

Jain, V.K.; Balasubramaniam, R.; Mote, Rakesh G.; Das, Manas; Sharma, A.; Kumar, Abhinav; Garg, Vivek; Kamaliya, Bhaveshkumar

doi:10.1177/2516598419895828

Cited by 15 publications

(2 citation statements)

References 77 publications

(85 reference statements)

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“…[1][2][3][4] In the last decades, there has been a significant advancement in various manufacturing processes such as focused ion beam machining, 5,6 electrochemical machining, 7 electric discharge machining, [8][9][10] and micromilling 11 for the manufacturing of complicated features. 12 All these processes have their own advantages and limitations in manufacturing. Another technique that overcomes several limitations of the abovementioned machining process is laser micromachining technique.…”

Section: Introductionmentioning

confidence: 99%

Analytical study for the selection of mask size and shape for obtaining high machining quality of complex features

Singh

Sharma

Kumar

et al. 2023

Journal of Micromanufacturing

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In this article, an analytical study of the effect of the shape and size of the mask on the machining quality of complex shapes has been carried out. For this study, we considered square and circular masks of varying sizes with varying overlap for the machining of square, inclined, and circular features. Mask size varied from 1 to 20 mm, while overlap varied from 10% to 90%. The machining quality of the aforementioned features was evaluated by studying the unmachined area “An” (in the machining zone) and the machining time “Tm.” For machining a similar feature, it was observed that the square mask performed much better than the circular mask in minimizing the machining time. However, the circular mask is much more suitable for minimizing the unmachined area. For validation, the experiment was conducted to machine the inclined lines with square and circular shape masks with varying overlap percentages. The experimental results were found to be in good agreement with the analytically obtained results, with an error of 2.5%. This study is relevant for the industrial-scale manufacturing of complicated features using the mask projection approach in laser machining.

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Section: Introductionmentioning

confidence: 99%

Analytical study for the selection of mask size and shape for obtaining high machining quality of complex features

Singh

Sharma

Kumar

et al. 2023

Journal of Micromanufacturing

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“…3 Out of the above processes, electrochemical micromachining (EMM) is gaining popularity for micro-tool fabrication. It removes material by an anodic dissolution process, which produces a surface with no residual stress, 4, 5 which is disadvantageous in thermal processes like EDM and laser machining. The fabrication of micro-tools with a diameter of less than 100 µm is often difficult in conventional machining as they get easily deformed due to the lateral force.…”

Section: Introductionmentioning

confidence: 99%

Effect of tool rotation on the fabrication of micro-tool by electrochemical micromachining

Kumar

Yadav

Kumar

et al. 2021

Journal of Micromanufacturing

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Electrochemical micromachining (EMM) uses anodic dissolution in the range of microns to remove material. Complex shapes that are difficult to machine on hard materials can be fabricated easily with the help of EMM without any stresses on the workpiece surface and no tool wear. Fabrication of microfeatures on microdevices is a critical issue in modern technologies. For the fabrication of microfeatures, precise micro-tools have to be fabricated. In this present study, EMM milling is used for the fabrication of micro-tools. For this, an EMM setup has been designed. Tungsten carbide tools with an initial diameter of 520 µm have been selected and are electrochemically machined to reduce their diameter. The tool and workpiece are connected as anode and cathode, respectively. The electrolyte solution used for this investigation is sodium nitrate. A comparative analysis of the effect of tool rotation over both machining accuracy and surface finish has been performed.

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