13-09-2012, 01:38 PM
Micromachining
MICRO.doc (Size: 201.5 KB / Downloads: 76)
INTRODUCTION
.
Micromachining is the basic technology for fabrication of micro-components of size in the range of 1 to 500 micrometers. Their need arises from miniaturization of various devices in science and engineering, calling for ultra-precision manufacturing and micro-fabrication.
Micromachining is used for fabricating micro-channels and micro-grooves (see Fig.) in micro-fluidics applications, micro-filters, drug delivery systems, micro-needles, and micro-probes in biotechnology applications. Micro-machined components are crucial for practical advancement in Micro-electromechanical systems (MEMS), Micro-electronics (semiconductor devices and integrated circuit technology) and Nanotechnology.
While mask-based processes can generate 2-D/2.5-D features on substrates like semiconductor chips, tools-based processes have the distinct advantage of being able to adapt to metallic and non-metallic surfaces alike, and also generate 3-D features and/or free-form sculpted surfaces. However, the challenges of achieving accuracy, precision and resolution persist.
Internationally, the race to fabricate the smallest possible component has lead to realization of sizes ever below 10 µm, even though the peak industrial requirement has been recognized at 100s of µm. thus, the present situation is particularly advantageous for the industry, as the following figure shows graphically.
Micromachining Process for Composites
Machining composites with conventional machine tools is challenging largely because composites have properties that require special approaches to milling and drilling. They are highly abrasive, meaning cutting tool life can be very low. Plus, the low-thermal-conductivity materials do not produce sizeable chips that carry heat away from a workpiece during machining. Thus, the wrong tool (or a worn one) can cause the material’s resin to burn or melt. Delamination and splintering are also issues given the material’s structure, which consists of resin-bound fibrous layers. In addition, cycle times for workpieces that require multiple machined features can be lengthy because milling and drilling operations create just one feature at a time. That means tooling costs can be high, too, especially when the part requires holes with many different diameters.
Waterjet is an option that provides more flexibility to do a variety of hole shapes and sizes, but the process still can lead to delamination. However, another versatile alternative, Photo-Machining, is now available to enable burr-free machining of composite parts that require multiple small features. The process was developed by Ikonics Micro Machining Solutions, a manufacturer located in Duluth, Minnesota.
MICRO.doc (Size: 201.5 KB / Downloads: 76)
INTRODUCTION
.
Micromachining is the basic technology for fabrication of micro-components of size in the range of 1 to 500 micrometers. Their need arises from miniaturization of various devices in science and engineering, calling for ultra-precision manufacturing and micro-fabrication.
Micromachining is used for fabricating micro-channels and micro-grooves (see Fig.) in micro-fluidics applications, micro-filters, drug delivery systems, micro-needles, and micro-probes in biotechnology applications. Micro-machined components are crucial for practical advancement in Micro-electromechanical systems (MEMS), Micro-electronics (semiconductor devices and integrated circuit technology) and Nanotechnology.
While mask-based processes can generate 2-D/2.5-D features on substrates like semiconductor chips, tools-based processes have the distinct advantage of being able to adapt to metallic and non-metallic surfaces alike, and also generate 3-D features and/or free-form sculpted surfaces. However, the challenges of achieving accuracy, precision and resolution persist.
Internationally, the race to fabricate the smallest possible component has lead to realization of sizes ever below 10 µm, even though the peak industrial requirement has been recognized at 100s of µm. thus, the present situation is particularly advantageous for the industry, as the following figure shows graphically.
Micromachining Process for Composites
Machining composites with conventional machine tools is challenging largely because composites have properties that require special approaches to milling and drilling. They are highly abrasive, meaning cutting tool life can be very low. Plus, the low-thermal-conductivity materials do not produce sizeable chips that carry heat away from a workpiece during machining. Thus, the wrong tool (or a worn one) can cause the material’s resin to burn or melt. Delamination and splintering are also issues given the material’s structure, which consists of resin-bound fibrous layers. In addition, cycle times for workpieces that require multiple machined features can be lengthy because milling and drilling operations create just one feature at a time. That means tooling costs can be high, too, especially when the part requires holes with many different diameters.
Waterjet is an option that provides more flexibility to do a variety of hole shapes and sizes, but the process still can lead to delamination. However, another versatile alternative, Photo-Machining, is now available to enable burr-free machining of composite parts that require multiple small features. The process was developed by Ikonics Micro Machining Solutions, a manufacturer located in Duluth, Minnesota.