1. Micro and Nano
Manufacturing
(7ME6.1A)- Part I
Mohit Ostwal
Assistant Professor
Department of Mechanical Engineering
Jodhpur Institute of Engineering and Technology- Coed, Jodhpur
11. Micro turning
• Characteristic Features and application
• Swiss-type machine tools, ultra-precision lathes for diamond
turning and miniature desktop machines, are used to perform
micro turning operations on parts made of different materials.
• Maximum Machining Diameter – 7 mm
Maximum Machining Length – 40 mm
• Hard to machine surfaces such as electroless nickel, glass ,
ceramics, quartz etc. without any subsurface damage.
• Mirror surfaces of less than 10 nm surface finish can be obtained.
• Ultra-precision diamond turning – electroless nickel dies – plastic
optical parts for LCD Tv’s (less than 6 nm)
12. Micro turning
• Micro turning tools and tooling system
• Miniaturized tools with clamping – Swiss type lathe or multi
purpose tooling system – Used as a tool block
• Monolithic carbide tools – boring and grooving – smallest
diameter of 0.2 mm to 4 mm maximum.
13. Micro turning
• Micro turning tools and tooling system (contd.)
• Special tooling system – turning, boring, cutt-off and drilling.
• System consists of clamping unit and cutting unit.
• Machine uptime reduce to 25-40%
15. Micro turning
Machine tools for micro turning
• In general – CNC automatic lathe, sliding head mechanism
• Swiss type Lathe
• Swiss type turning centers with milling, drilling, boring – single setup with lower
cost –upto 4mm dia..
• Sliding head stock – 32 mm max. dia. with bar feeder.
• 12000 rpm – with guide bushes and 16000 rpm without guide bushes.
• 10000 rpm – sub spindles for milling, drilling.
20. Micro drilling
• Characteristic Features and application
• Holes – tens of micrometers – PCB
• Inkjet printers – single row of 251 holes – 50 μm dia.
• Used below 0.5 mm.
• Minimum diameter of micro drills -> 5-50 μm.
• Advantages of micro drilling:
1. Metals, plastics and composites can be drilled – electrical
properties do not influence the workpiece (wire EDM).
2. Controllability
• Disadvantages of micro drilling:
1. Inclination of holes
2. Brittle and hard materials – break micro drills – diamond drills.
21. Micro drilling
• Microdrills and tooling system
• HSS(resistant to breaking) to carbide(stiffer but brittle).
• Diameter range – 0.12 mm to 2.8 mm.
• Drilling of Aircraft Al, Titanium, SS, Steel.
• 10 mm length with shank.
23. Micro drilling (contd.)
Micro drills of the smallest obtainable diameter of approximately 6 μm with a D-shape
cross-section and a cutting edge radius of 0.5 μm can be fabricated by wire
electro-discharge grinding
32. Micro milling example
• Used to create 3D features in the range of a few microns to a few
hundred microns.
• Micro milling is capable of the fabricating holes several tens of
micrometers in size for practical applications.
33. Micro manufacturing example
• A mite measuring 500m long sits on a mirror array used for optical data switching.
• The mirror [flat in the left image, folded in the right] is positioned with a gear mechanism
34. A focused ion beam created this two-micron-wide gear,
seen here at 50,000x magnification