Review on cryogenic assisted micro-machining of soft polymer: An emphasis on molecular physics, chamber design, performance analysis and sustainability

Mallick, Partha Sarathi; Pratap, Ashwani; Patra, Karali

doi:10.1016/j.jmapro.2022.06.035

Cited by 10 publications

(7 citation statements)

References 70 publications

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“…The detail explanation of the Fig. 2 is already discussed in previous study by Mallick et al [5]. The notion of present study is that to machine VHB at small temperature zone of glass transition region where high quality surface nish and chip formation in ductile mode could be possible.…”

Section: Principle Of Materials Removal Mechanism Of Vhbmentioning

confidence: 66%

“…From semi-crystalline state near T g to glassy state below T g , cutting force increases linearly. The increase of forces were resulted due to increase of stiffness below glass transition temperature T g [5]. According to the above analysis, the temperature of the workpiece should be controlled in the temperature range of -38 0 C to -42 0 C, during micro-milling of VHB and the cold ow region of the glass transition zone can be considered to be within this temperature range.…”

Section: Analysis Of Surface Roughnessmentioning

confidence: 99%

“…Materials that undergo deformation eventually return to their original positions due to viscoelastic behaviour at ambient temperature. Because of this, viscoelastic soft polymers require a change in mechanical properties that will allow for the material to be machined in a shearing-dominant mode while maintaining the exact position of the machined geometries [5]. Kakinuma et al [6] proposed cryogenic micromachining of polydimethylsiloxane (PDMS) polymer by complete immersion of the workpiece inside liquid nitrogen as a direct process to fabricate microchannel.…”

Section: Introductionmentioning

confidence: 99%

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Influences of size effect and workpiece temperature during cryogenic micro milling of soft viscoelastic polymer: An experimental assessment

Mallick,

Patra

2024

Preprint

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It is necessary to create different micro-features on stretchable polymers for making sensing components in wearable sensors, and to make them work like human tissue. Such micro-features are currently fabricated through soft lithography process that requires long processing time. However, tool based micromachining which is faster and able to create any customized and complex structures has not yet been applied as soft polymer shows high adhesion and low elastic modulus at room temperature. This study aims to evaluate the machinability of typical viscoelastic soft polymer and understand the effect of material and process parameters on machining performances. In this study, a mechanical micro milling process using cryogenic assisted cooling is proposed and the importance of temperature control towards glass transition zone was particularly addressed. To identify insight of machinability in micro domain, this article also determines minimum uncut chip thickness (MUCT) and size effects by considering the variations of cutting force and surface integrity with the ratio of h/re (uncut chip thickness (h) to cutting edge radius (re)). The experimental results reveal that consideration of size effect during micro milling of soft viscoelastic polymer helps in reduction of machined surface roughness (Sa) value. Based on the cutting force pattern, it is evaluated that higher machining stability can be achieved during cryogenic machining by reduction of specific cutting force value. By control tuning of temperature, machining performances exact at glass transition temperature zone show more promising experimental results compared to other cooling zones.

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Section: Principle Of Materials Removal Mechanism Of Vhbmentioning

confidence: 66%

Section: Analysis Of Surface Roughnessmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Influences of size effect and workpiece temperature during cryogenic micro milling of soft viscoelastic polymer: An experimental assessment

Mallick,

Patra

2024

Preprint

Self Cite

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“…Micro-machining technologies based on tools, including micro-milling, micro-turning, micro-grinding, and micro-drilling, operate on principles similar to those of traditional machining processes [ 29 , 30 , 31 , 32 ]. Mechanical micro-machining processes provide flexibility, making it possible to fabricate miniature components with intricate geometries, regardless of the material’s nature.…”

Section: Introductionmentioning

confidence: 99%

“…Mechanical micro-machining processes provide flexibility, making it possible to fabricate miniature components with intricate geometries, regardless of the material’s nature. The process thus promises versatility and precision in crafting micro-components for biomedical applications [ 31 ].…”

Section: Introductionmentioning

confidence: 99%

Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy

Ercetin,

Aslantaş,

Özgün

et al. 2023

Micromachines

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This comprehensive study investigates the micro-milling of a Mg13Sn alloy, a material of considerable interest in various high-precision applications, such as biomedical implants. The main objective of the study was to explore the optimizations of variable feed per tooth (fz), cutting speed (Vc), and depth of cut (ap) parameters on the key outcomes of the micro-milling process. A unique experimental setup was employed, employing a spindle capable of achieving up to 60,000 revolutions per minute. Additionally, the study leveraged linear slides backed by micro-step motors to facilitate precise axis movements, thereby maintaining a resolution accuracy of 0.1 μm. Cutting forces were accurately captured by a mini dynamometer and subsequently evaluated based on the peak to valley values for Fx (tangential force) and Fy (feed force). The study results revealed a clear and complex interplay between the varied cutting parameters and their subsequent impacts on the cutting forces and surface roughness. An increase in feed rate and depth of cut significantly increased the cutting forces. However, the cutting forces were found to decrease noticeably with the elevation of cutting speed. Intriguingly, the tangential force (Fx) was consistently higher than the feed force (Fy). Simultaneously, the study determined that the surface roughness, denoted by Sa values, increased in direct proportion to the feed rate. It was also found that the Sa surface roughness values decreased with the increase in cutting speed. This study recommends a parameter combination of fz = 5 µm/tooth feed rate, Vc = 62.8 m/min cutting speed, and ap = 400 µm depth of cut to maintain a Sa surface roughness value of less than 1 µm while ensuring an optimal material removal rate and machining time. The results derived from this study offer vital insights into the micro-milling of Mg13Sn alloys and contribute to the current body of knowledge on the topic.

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Lead and cadmium decontamination from water media by CNT/Starch/Fe3O4, as reclaimable magnetic nanocomposite

Zhang

2024

Biomass Conv. Bioref.

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Review on cryogenic assisted micro-machining of soft polymer: An emphasis on molecular physics, chamber design, performance analysis and sustainability

Cited by 10 publications

References 70 publications

Influences of size effect and workpiece temperature during cryogenic micro milling of soft viscoelastic polymer: An experimental assessment

Influences of size effect and workpiece temperature during cryogenic micro milling of soft viscoelastic polymer: An experimental assessment

Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy

Lead and cadmium decontamination from water media by CNT/Starch/Fe3O4, as reclaimable magnetic nanocomposite

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