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Nagahanumaiah,
- Micro-Nano Patterning of Solid Surfaces for Enhanced Antibacterial Properties-Challenges and Opportunities
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Authors
Affiliations
1 Micro Systems Technology Laboratory, CSIR-Central Mechanical Engineering Research Institute, Durgapur, IN
1 Micro Systems Technology Laboratory, CSIR-Central Mechanical Engineering Research Institute, Durgapur, IN
Source
Manufacturing Technology Today, Vol 13, No 11 (2014), Pagination: 3-9Abstract
Bacteria resistant films and coatings being used today are highly toxic to the human body. Micro-nano patterns deliberately created over solid surfaces that counter microbial activity is an emerging technology in preventing hospital acquired infections (HAI), to provide personalized healthcare. This paper is focused on defining the optimized surface topologies and micro-nano patterning over solid surfaces. Preliminary studies on designing surface topologies and micro-nano patterning has been carried out. The feasibility of adopting nano-scratching, micro-milling, micro-EDM and laser machining for direct patterning over amorphous bulk metallic glass (BMG) and PDMS is investigated. Effect of pattern geometry on bacterial physiology and opportunities for integrating these mechanical based micro-nano manufacturing protocols are discussed.Keywords
Surfaces, Micro-Nano Patterning, Bulk Metallic Glass (BMG).
- A Study on Porosity in Micro-Selective Laser Sintering of Copper Powder
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Authors
Affiliations
1 School of Laser Science and Engineering, Jadavpur University, Kolkata, IN
2 Central Manufacturing Technology Institute, Bangalore, IN
3 Production Engineering Department, Jadavpur University, Kolkata, IN
1 School of Laser Science and Engineering, Jadavpur University, Kolkata, IN
2 Central Manufacturing Technology Institute, Bangalore, IN
3 Production Engineering Department, Jadavpur University, Kolkata, IN
Source
Manufacturing Technology Today, Vol 18, No 1 (2019), Pagination: 3-9Abstract
In Selective Laser Sintering metal powder particles are consolidated layer-by-layer through laser heating. In recent years, process has been improved that addressed the defects such as porosity, micro-cracks etc., resulting its wider applications in industries. However, there is a promising opportunity exists to use this process in micro manufacturing, which has not been exploited to a great extent. In this work, an attempt has been made to understand the porosity defects formed in micro-selective laser sintering (Micro-Sintering) of copper powder. Molecular Dynamics based simulation study performed for the Micro-Sintering of nano-scale powders has shown insight into the mechanism of neck growth formation and resulting porosity on their joining with adjacent particles. The other defects such as cracks formation, balling effects, presence of residual binders contributing to porosity and micro-cracks observed during experimental study on Micro-Sintering of 5μm copper powder has also been discussed.Keywords
Selective Laser Sintering, Copper, Defects, Porosity, Molecular Dynamics Simulations.References
- Chang, S; Li, L; Lu, L; Fuh, J Y H: Selective Laser Sintering of Porous Silica Enabled by Carbon Additive, 'Materials', 2017, 10 (11), 1313.
- Duan, B; Wang, M: Selective laser sintering and its application in biomedical engineering, 'MRS bulletin', 2011, 36(12), 998-1005.
- Kasperovich, G; Haubrich, J; Gussone, J; Requena, G: Correlation between porosity and processing parameters in TiAl6V4 produced by selective laser melting, Materials & Design, 2016, 105, 160-170.
- Ko, SH; Pan, H; Grigoropoulos, CP; Luscombe, CK; Fréchet, JM; Poulikakos, D: All-inkjet-printed flexible electronics fabrication on a polymer substrate by lowtemperature high-resolution selective laser sintering of metal nanoparticles, 'Nanotechnology', 2007, 18(34), 345202.
- Koo, B.-U; Yi, Y; Lee, M; Kim, B.-K: Effects of particle size and forming pressure on pore properties of Fe-Cr-Al porous metal by pressureless sintering, Metals and Materials International, 2017, 23(2), 336-340.
- Paul, S; Nagahanumaiah, Mitra, S; Roy, D; Molecular Dynamics Simulation Study of Neck Growth in Micro-selective Laser Sintering of Copper Nanoparticles, Simulations for Design and Manufacturing, Dixit U., Kant R. (Eds), 2018, 259-292, Springer, Singapore.
- Read, N; Wang, W; Essa, K; Attallah, MM: Selective laser melting of AlSi10Mg alloy: Process optimisation and mechanical properties development, 'Materials & Design', 2015, (1980-2015), 65, 417-424.
- Regenfuss, P; Ebert, R; Exner, H; Laser micro sintering–a versatile instrument for the generation of microparts, 'Laser Technik Journal', 2007a, 4(1), 26-31.
- Regenfuss, P; Streek, A; Hartwig, L; Klötzer, S; Brabant, T; Horn, M; Ebert, R; Exner, H; Principles of laser micro sintering, Rapid Prototyping Journal, 2007b, 13(4), 204-212.
- Regenfuss, P; Streek, A; Hartwig, L; Klötzer, S; Brabant, T; Horn, M; Ullmann, F; Ebert, R; Exner, H: Material depending mechanisms in laser micro sintering, 'Proceedings of the 5th LANE', 2007c, 403-418, Erlangen, Germany.
- Shaw, B and S. Dirven (2016). Investigation of porosity and mechanical properties of nylon SLS structures, Proceedings of 23rd International Conference on Mechatronics and Machine Vision in Practice (M2VIP 2016), 208213, IEEE, Nanjing, China.
- Song, JL; Li, YT; Deng, QL; Hu, DJ: Rapid prototyping manufacturing of silica sand patterns based on selective laser sintering, Journal of Materials Processing Technology, 2007, 187, 614-618.
- Wei, S: Bangchao, Y., Xuanhong, Z., Jianhua, M., Qifeng, P; Xingwei, W: Effect of Sintering Time on the Microstructure of Porous Tantalum, 'Rare Metal Materials and Engineering', 2015, 44 (2), 319-322.
- Yan, W; Li, N; Li, Y; Liu, G; Han, B; Xu, J: Effect of particle size on microstructure and strength of porous spinel ceramics prepared by pore-forming in situ technique, Bulletin of Materials Science, 2011, 34 (5), 1109-1112.
- Fibre Bragg Grating Sensors for Measuring Spark Gap in Micro-EDM in Real-Time
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Authors
Affiliations
1 CSIR-Central Mechanical Engineering Research Institute, Durgapur, IN
2 Central Manufacturing Technology Institute, Tumkur Road, Bengaluru, IN
1 CSIR-Central Mechanical Engineering Research Institute, Durgapur, IN
2 Central Manufacturing Technology Institute, Tumkur Road, Bengaluru, IN
Source
Manufacturing Technology Today, Vol 18, No 7 (2019), Pagination: 3-8Abstract
In the phase of Industry 4.0 (I.4) technology, miniaturization has paved the foundation of the smart manufacturing sector and the micromachining processes can be considered as the front end of the I.4 technologies. Micro-Electric Discharge Machining (Micro-EDM) has been considered the most promising micromachining technology for fabrication of microfeatures irrespective to hard and temperature resistive materials. The process characteristics in Micro-EDM is very stochastic in nature, and understanding the proper process characteristics with digitization of data to predict the process for improved capabilities is highly required in this era of Industry 4.0 revolution. The spark discharge between the anode and cathode is envisaged to be very small gap (~10μm) and also an essential parameter for machining performance, but measurement of spark gap of Micro-EDM in realtime is a great challenge. This present work is based on measurement of spark gap with a novel sensing technique based on Fiber Bragg Grating (FBG).Keywords
Micro-EDM, Spark Gap Measurement, FBG Sensor.References
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- A Review on Short Pulse Generator Used for Micro Electric Discharge Machining
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Authors
Affiliations
1 CSIR- Central Mechanical Engineering Research Institute (CMERI), Durgapur, West Bengal, IN
2 Academy of Scientific and Innovative Research (AcSIR) Anusandhan Bhawan, New Delhi, IN
3 Central Manufacturing Technology Institute (CMTI), Bengaluru, Karnataka, IN
1 CSIR- Central Mechanical Engineering Research Institute (CMERI), Durgapur, West Bengal, IN
2 Academy of Scientific and Innovative Research (AcSIR) Anusandhan Bhawan, New Delhi, IN
3 Central Manufacturing Technology Institute (CMTI), Bengaluru, Karnataka, IN
Source
Manufacturing Technology Today, Vol 18, No 12 (2019), Pagination: 3-11Abstract
Micro-EDM is a promising noncontact micro machining process; where the precisely controlled electric spark occurred between the tiny electrodes and erodes the material from electrically conductive work piece. Application of this Micro EDM is rapidly growing in manufacturing of metal products irrespective of its hardness having geometric features in range of micrometer to nanometer scale. In order to ensure the material removal in the order of few cubic micrometers it is desirable to use a low energy, shorter pulsed discharges at very high frequency. In this study, the detailed literature review related to low energy and short pulsed power circuits to use in Micro-EDM process conditions has been carried out. The advantages and issues of obtaining such high frequency short pulsed low energy discharge have been critically studied to set the future directions for further investigation.Keywords
Micro EDM, Pulse Generator, RC Relaxation Circuit, Transistor Type Pulse Generator.References
- Ho, KH and Newman, ST: State of the art electrical discharge machining (EDM), 'Int. J. Mach. Tools Manuf.', vol. 43, no. 13, 2003, 1287-1300, .
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- Study on Material Removal Rate and Surface Roughness using Graphene as Dielectric Additives in Micro-Electric Discharge Machining
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Authors
Affiliations
1 CSIR-Central Mechanical Engineering Research Institute, Durgapur, West Bengal, IN
2 Central Manufacturing Technology Institute, Tumkur Road, Bangalore, Karnataka, IN
1 CSIR-Central Mechanical Engineering Research Institute, Durgapur, West Bengal, IN
2 Central Manufacturing Technology Institute, Tumkur Road, Bangalore, Karnataka, IN
Source
Manufacturing Technology Today, Vol 20, No 11-12 (2021), Pagination: 3-9Abstract
Micro-electric discharge machining is the most distinguished micro-manufacturing process for engineering micro-parts of different geometric features. The slow material removal rate owing to the low energy short-pulsed electric discharge is the major bottleneck of the process in batch scale production. This paper is an attempt to increase the material removal rate (MRR) and enhance the surface integrity in micro-EDM using graphene as an additive in dielectric liquid. Graphene sheets synthesized using Hummers method followed by reduction and subsequent heating was dispersed in hydrocarbon based dielectric liquid by ultrasonication at temperature near to the flash point. The INCONEL 718 workpiece electrode has been immersed in the graphene suspended dielectric medium where as tungsten carbide of diameter 200µm has been used as tool electrode. It has been found that the MRR increases by 47 % in terms of volume of material removed and the surface roughness reduces by 73 % for graphene additive based dielectric medium as compared with dielectric without additive.Keywords
Micro-EDM, MRR, Surface Roughness, Graphene, Dielectric Medium.References
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- Chounde1, A. B., & Pawar, M. M. (2014). Study of Pulsed DC Power Supply Parameters for Micro-EDM. International Journal of Advanced Research in Electrical, Electronics and Instrumentation Engg., 3(10), 12493-12495.
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- Jahan, M. P., Anwar, M. M., Wong, Y. S., & Rahman, M. (2009). Nanofinishing of hard materials using micro-electrodischarge machining. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 223(9). https://doi.org/10.1243/09544054JEM1470
- Jahan, M. P., Rahman, M., & Wong, Y. S. (2010). Modelling and experimental investigation on the effect of nanopowder-mixed dielectric in micro-electrodischarge machining of tungsten carbide. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 224(11), 1725–1739. https://doi.org/10.1243/09544054JEM1878
- Kibria, G., Sarkar, B. R., Pradhan, B. B., & Bhattacharyya, B. (2010). Comparative study of different dielectrics for micro-EDM performance during microhole machining of Ti-6Al-4V alloy. International Journal of Advanced Manufacturing Technology, 48(5), 557-570.
- Kolli, M., & Kumar, A. (2015). Effect of dielectric fluid with surfactant and graphite powder on Electrical Discharge Machining of titanium alloy using Taguchi method. Engineering Science and Technology, an International Journal, 18(4), 524-535. https://doi.org/10.1016/j.jestch.2015.03.009
- Kurnia, W., Tan, P. C., Yeo, S. H., & Tan, Q. P. (2009). Surface roughness model for micro electrical discharge machining. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 223(3), 279-287. https://doi.org/10.1243/09544054JEM1188
- Mahendran. S., Devarajan. R., Nagarajan, T., & Majdi, A. (2010) - A Review of Micro-EDM. Proceedings of the International MultiConference of Engineers and Computer Scientists 2010 Vol II, IMECS 2010, March 17 - 19, 2010, Hong Kong
- Manikandan, R., & Venkatesan, R. (2012). Optimizing the machining parameters of micro EDM for Inconel 718. Journal of Applied Sciences, 12(10),971-977.
- Nagahanumaiah, Ramkumar, J., Glumac, N., Kapoor, S. G., & Devor, R. E. (2009). Characterization of plasma in micro-EDM discharge using optical spectroscopy. Journal of Manufacturing Processes, 11(2), 82-87. https://doi.org/10.1016/j.jmapro.2009.10.002
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