Demand For Micro-components Research Articles

Experimental Evaluation of the Feasibility and Reproducibility of a Novel Multi-step Forming Process for Cu-OFE Micro Gear Manufacturing Compared to Macro-scale Forming

The increasing miniaturization of technical systems leads to a rising demand for micro components. Miniaturized drive systems with geared micro parts or micro gears are applied in various industries. Due to the demand for high production volumes, productive and resource-efficient fabrication is of major importance. Compared to industrially applied manufacturing methods like cutting and metal powder injection, cold forming provides technological, economic and ecological potential for the mass production of micro gears. It enables high productivity and advantageous mechanical properties of the gears. In the macroscopic size range, forming processes are well established in series production of gears. However, in micro-scale, according to the current state of the art, cold forming of modules m<0.2mm is not possible due to size effects, high tool loads and handling problems. Within this contribution, a multi-stage forming process for the fabrication of micro gears with a module of m=0.1mm is introduced and compared with a conventional forming process on macro-scale with a module of m=1.0mm. The use of coil material provides potential for easy handling of the micro parts in a progressive die for the potential application in a high-speed press. In addition, the multi-stage forming achieves a grain alignment, which enhances the formation of the micro gear profile. Based on the comparison between micro- and macro-scale, the performance of the micro process is analyzed with regard to deviations of process force as well as gear quality and possible size effects are identified. The results prove the feasibility of the process chain and the achievement of equivalent part quality and reproducibility compared to macro-scale forming.

Analysis of chip morphology to understand the machining mechanism of micro end milling while machining Ti-6Al-4V

Increasing demand for micro components and micro features has been on the rise due to the introduction of newer products and technologies. In order to cope up with this high demand, an efficient and high productive manufacturing technique is required. Micro end milling is considered to be one of the preferred micro machining techniques as it can easily produce complex 3D features. Even though micro milling is considered to be the downscaled version of the conventional macro milling process there is a significant difference in the machining mechanism when it comes to the micro machining process. This paper mainly focused on understanding the machining mechanism of micro end milling process by analysing the chip morphology. In micro end milling process it was observed that the feed/tooth and edge radius of the tool has got a significant influence on the machining mechanism. For feed/tooth much below the edge radius of the tool, ploughing is dominant and for feed/tooth greater than that of edge radius shearing mechanism is predominant. This was evident in the chip morphology. Similarly, influence of tool wear on chip morphology and thereby correlating with the machining mechanism was investigated. It was noted that enlargement of edge radius of the tool due to tool wear is also considered to be one of the tool wear modes in micro machining process.

Size effect and micro endmilling performance while sustainable machining on Inconel 718

ABSTRACT Micro endmilling is emerged as a potential micromachining technique in many industries like biomedical, aerospace, optics, electronics and marine, etc. due to the huge demand for micro components with precision. However, relatively higher tool wear and poor surface characteristics are limiting its applicability in many areas. Therefore, the need has been raised to improve the machining characteristics of micro endmilling sustainably. The size effect and micro endmilling performance such as wear behavior, cutting force, and microhardness under dry and sunflower oil based MQL environments while machining on Inconel 718 was studied in this work. Results showed that the sunflower oil based MQL environments have the potential to reduce the size effect region and tool wear significantly. Workpiece adhesion and abrasion on the cutting edge were identified as the main underlying wear mechanism for both conditions. The edge radius, tool flank wear, and cutting forces were found to be reduced by 25%, 30%, and 36% respectively with the application of MQL compared to dry conditions. In addition, an increase of 7% in microhardness with relatively smooth surfaces as well as reduced micro cracks, prows, and voids on the machined surfaces were observed with the application of MQL.

Analysis of the Forces in Micromilling of Hardened AISI H13 Steel with Different Grain Sizes Using the Taguchi Methodology

The micromachining process has been applied to the free form and micromolds markets. This has occurred due to the growth in demand for microcomponents. However, micromachining of hardened steels is a challenge due to the reduction in tool life and the increase of the surface roughness when compared with the macromachining process. This paper focused on the analysis of micromilling forces on hardened AISI H13 steel with different grain sizes. Experimental tests were carried out on workpieces with different austenitic grain sizes and a hardness of 46 HRC. Micro-end-mill cutters with a diameter of 0.5 mm and (TiAl)N coatings were applied in the milling of workpieces of 11 × 11 mm. The input parameters were two radial depths of cut, two cutting speeds, and two feed rates. The influence of the input parameters on the response cutting force was analyzed using the Taguchi method. Finally, considering the large grain size, the cutting forces in the x-, y-, and z-axes direction were small.

One- and two-component micro powder injection moulding derived from thermoplastic microreplication

Today, microinjection moulding represents an established special variant among the different replication techniques strongly promoted by the growing market demand for microcomponents. Spearheading progress towards more sophisticated technologies, micro powder injection moulding offers a large scale fabrication process for metal/ceramic microparts. Minimal details in the range of 10 μm and replication accuracy down to ±0·3% (in special cases, ±0·1%) can be reached. With a twofold aim of reducing mounting costs and enabling the production of highly integrated devices two-component microinjection moulding is under development. Interesting examples are immovable or movable ceramic shaft wheel components.