Manufacturing Technology Today

K. Niranjan Reddy ¹, N. Balashanmugam ¹, P. V. Shashikumar ¹

Affiliations
1 Central Manufacturing Technology Institute, Tumkur Road, Bangalore, IN

Abstract

With the objective of catering the R&D needs of machine tools and allied areas in focus, along with the basic infrastructure of the institute, various laboratories including metrology laboratory were setup in CMTI to support developmental activities and to assist prototype workshop. With the advancement of time, these laboratories started catering to the needs of industries throughout India. Over last 5 decades, CMTI had significantly contributed in Product development, Technology development, Training, Framing Standards, Development of Artefacts in Metrology field. CMTI has been a forerunner in all the above aspects in the country particularly in dimensional and surface metrology.

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K. Niranjan Reddy ¹, Nithin Narayanan ², P. V. Shashi Kumar ¹, Sudhakar C. Jambagi ²

Affiliations
1 Micro Engineering & Nano Technology Department, Central Manufacturing Technology Institute, Tumkur Road, Bangalore, IN
2 National Institute of Technology Karnataka, Surathkal, IN

Abstract

Coordinate Measuring Machine (CMM) is a measuring system with a movable probing system and capability to determine spatial coordinates on a work piece surface, that can be further analyzed to arrive at the required parameters. As geometry of feature is not ideal, the number of points, their distribution and their computation method have an effect on the results of dimension, form and position and therefore on also coordinate system. Discrete point probing uses only few points to calculate the ideal circle; the outcome of this is incorrect information on form shape. For features having functional requirement like assembly, running accuracy form is critical and true shape of the feature is required. Hence, CMMs are developed with scanning feature; which supplies the large data quantities for evaluation. The optimization of scanning parameters like number of points for a feature is one of the important parameters in the coordinate metrology. The aim of the paper is to describe the effect of number of points for scanning a feature and optimization of this scanning parameter and to adopt the optimized scanning data to the discrete point probing system.

Keywords

CMM, Scanning, Discrete Point Probing, Form, Feature, Optimization.

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N. Balashanmugam ¹, K. Ankit ¹, K. Niranjan Reddy ¹, V. Shanmugaraj ¹, P. V. Shashi Kumar ¹

Affiliations
1 Central Manufacturing Technology Institute, Bangalore, IN

Abstract

Productivity in manufacture of high aspect ratio cylinders depends on how quickly the inspection parameters are measured and corrective actions are token. Long cylinders undergo a series of processes including bend removal and machining. These processes undergo a series of iterations consuming considerable amount of time for the measurement of straightness of cylinder. In this paper, a concept is proposed, where, the straightness of the bore of a cylinder (barrel) is measured in-situ on the machine. In this method, the barrel diameter and thickness are measured at number of planes using touch trigger probe and ultrasonic transducer respectively. Ultrasonic transducer assembly and the touch trigger probe are mounted on the turret of the CNC Turn Mill Centre. The setup for ultrasonic based measurement includes a nozzle for the supply of stream of liquid on the work piece, an ultrasonic transducer and a data capturing unit. Echo from ultrasonic waves is obtained back from the stream enabling the measurement of the relative position from the outer profile of the work piece to its internal profile. By orienting (rotating) the work piece at different locations in the same plane, thickness and diameters are measured. Straightness is measured by continuing to measure along the length of the cylinder. The thickness and diameters obtained are then used for the evaluation of straightness of the bore.

Keywords

Straightness, Cylinder, Touch Trigger Probe, Ultrasonic Transducer.

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K. Niranjan Reddy ¹, P. V. Shashi Kumar ¹, Somashekar Rao ¹

Affiliations
1 Micro Engineering and Nano Technology Dept., Central Manufacturing Technology Institute, Tumkur Road, Bangalore, IN

Abstract

Today, wire EDM is providing the most economical solution for manufacture of Dies, Punches and special tools required in almost all the engineering industries. Often, Wire EDM is found to be the only solution for parts, which are extremely difficult or Impossible to handle with any other method of machining. Now, the same process is found to be Ideally suited for manufacture of micro components. These products require very high surface finish, profile accuracy and smallest possible radius In the corners. With the continuous refinement and innovations in the technology, the design of the machine, the spark generator and the operation software the Micro finish and Micro Wire EDMs have been developed. This paper gives the main features of the Micro Finish & Micro wire EDM and the some of the parts machined on this type of machine, which give insight to the use of this type of machine In precision manufacturing.

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K. Niranjan Reddy ¹, P. V. Shashi Kumar ¹

Affiliations
1 Micro Engineering & Nano Technology Department, CMTI, Bangalore, IN

Abstract

In Non Destructive Testing (NDT) ultrasonic flaw detectors are extensively used for inspection of metallic raw materials like forgings, castings and rolled sections for internal imperfections and defects like cracks, voids, inclusions etc. In these Ultrasonic flaw detectors Ultrasonic standard reference blocks are used as masters for allowable level of flaws in metallic raw materials. These reference blocks are also used for calibration of flaw detectors. These reference blocks are made with precisely drilled flat bottom holes (FBH) of different diameters depending on the allowable level of flaws. Reference blocks with flat bottom holes of dia from 2 mm down to dia 0.5 mm are mainly used in aerospace applications. These blocks are to be made in the same material that is to be inspected. The typical test materials are Aluminium, Steel, Titanium and Nickel base alloys. This paper deals with micro-drilling of 0.5 mm diameter flat bottom holes in Titanium material Ultrasonic Standard Reference Blocks.

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K. Niranjan Reddy ¹, K. Chandran ²

Affiliations
1 Precision Engineering and Nano Technology Department, Central Manufacturing Technology Institute, Bangalore-560022, IN
2 Aircraft Research and Design Centre, HAL, Bangalore-560037, IN

Abstract

Ultrasonic standard reference blocks are extensively used in calibration and performance evaluation of Ultrasonic flaw detectors. They are also used in inspection of metallic raw materials like forgings, castings and rolled sections apart from machined components for any flaws like cracks, inclusions etc. These reference blocks consist of precisely drilled flat bottom holes (FBH) to act as intentional flaws and they are made from the same material that is to be inspected to get the same acoustic response. The typical test materials are Titanium alloys, Copper alloys, Aluminium alloys and Steels. Ultrasonic response tests are carried out for studying the intensity of the returned echo from the flat bottom, over different metal travel distances. Reference blocks with flat bottom of dia from 2 mm down to 0.5 mm are used mainly in aerospace applications. This paper deals with the manufacturing and inspection techniques employed in the indigenous development of Titanium Alloy reference blocks of 1.2 mm FBH.

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Sunil Magadum ¹, K. Niranjan Reddy ¹, M. Chellamalai ¹, N. Balashanmugam ¹

Affiliations
1 Central Manufacturing Technology Institute (CMTI), Bengaluru, Karnataka, IN

Abstract

Standard glass scale is just like a kind of very precise ruler and on its surface, accurate divisions are equally marked. The standard glass scales are frequently used in calibration of precise instruments with non contact method of measurements like optical microscopes, video microscopes, profile projectors etc. With the help of ultra fast pulsed laser micromachining system devised a state of the art process for manufacturing standard glass scales. The machined standard scales were calibrated using F25 CMM for 10 mm range scale and Profile projector for 150 mm range scale. The results of the calibration shows the accuracy of the Glass scales at par with the scales manufactured by photolithography process.

Keywords

Standard Glass Scale, Gratings, Stage Micrometers, Ultra Fast Pulsed Laser.

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K. Ankit ¹, K. Niranjan Reddy ¹, Gokul ², N. Balashanmugam ¹

Affiliations
1 Central Manufacturing Technology Institute (CMTI), Bengaluru, IN
2 National Institute of Technology Karnataka (NITK), Surathkal, IN

Abstract

Carbon Nano Tubes (CNTs) were deposited on Silicon substrate by RF plasma enhanced chemical vapour deposition (RF-PECVD). The deposition was carried out at 550 V bias and 600°C with C₂H₂ precursor gas diluted with H₂ in the ratio of 1:4. Transition metal catalysts are required for CNT growth by PECVD. It is believed that the catalyst on the substrate must be in the form of particles instead of smooth, continuous films. The eventual particle size and the resultant nanotube diameter correlates to film thickness. Thinner films in general lead to smaller particles and tube diameters. While a small grain size is not guaranteed in as-prepared films, steps are taken to break the film into desired particles to form island like structures. This work investigates the effect of Nucleation and the time interval of Nucleation on the CNT growth process.

Keywords

CNT, Nucleation, RF-PECVD

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R. Vignesh ¹, Sunil Magadum ¹, K. Niranjan Reddy ¹

Affiliations
1 Central Manufacturing Technology Institute, Bengaluru, Karnataka, IN

Abstract

Globally neurological diseases are increasing due to unhealthy lifestyles, environmental influences, and physical injuries. So, MEA (microelectrode array) based neural interface systems can restore the lost neural functions to treat neurological diseases through stimulating or recording a neuronal signal. In 1664 Jan Swammerdam was the first to explain nerve function and nerve stimulation. Nowadays, many neural recording systems are available for interfacing with the brain. These systems can be classified into two ways: intracellular or extracellular recording. The extracellular recording is the technique of recording or stimulating the neural signals by placing the electrode near the tissues or cells. It is a less invasive approach compared to an intracellular recording. Generally, the neural interface systems are classified as the CNS (central nervous system) and PNS (peripheral nervous system). Microelectrode arrays can interface in the central nervous system to treat neurological diseases. A mechanical mismatch is a significant problem that arises during the insertion of the implant into the brain tissue. So, various surface modification techniques are considered a viable solution among researchers to address this issue. Also, laser and EDM-based new fabrication techniques are getting more attention over photolithography techniques for reducing the fabrication timing, cost, and usage of hazardous chemicals.

Keywords

Microelectrode Array, Neural Interface Systems, Laser and EDM Fabrication Techniques, Surface Modification.

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