STUDY ON THE MICRO TOOLING SYSTEM AND OPTIMIZATION OF MICRO/NANO MILLING PROCESSES

Researcher: Xiang ChengXiangCheng.bmp

Start date:    November 2006

End date:      April 2011

Keyword:     Micro tool, PCD, WEDM,

                    Micro/nano machining

Objectives

Improve accuracy, productivity and stability for micro/nano milling of hard and brittle materials by researches on micro tooling and micro/nano milling processes.

Abstract

Micro/nano machining of hard and brittle materials (WC or Silicon) needs PCD (or CBN) micro tools. Tool geometry needs to be customized in order to realize ductile-mode machining. In my research, based on the specially designed six-axis WEDM machine, the custom tool CAM system was developed considering the parametric micro tool design and the error compensation for the WEDM machine. Then, custom micro tool development procedure was introduced and typical straight edge end mills and ball end mills have been successfully developed. Micro freeform geometry and nano meter level surface finish has been achieved by the developed micro end mills. Further studies are being processed for the deep understanding of the ductile-mode machining of hard and brittle materials in order to guide the efficient custom micro tooling and micro/nano milling processes.

Results

  1. DESIGN AND DEVELOPMENT OF MICRO PCD BALL END MILL FOR MICRO/NANO FREEFORM MACHINING OF HARD AND BRITTLE MATERIALS
    X. Cheng, Z.G. Wang, K.Nakamoto, K. Yamazaki
    Journal of Micromechanics and Microengineering, (Under review)
    Institute of Physics, 2009.
  2. DEVELOPMENT OF A SIX-AXIS WIRE ELECTRICAL DISCHARGE MACHINING MACHINE FOR THE FABRICATION OF MICRO END MILLS
    X. Cheng, Z.G. Wang, S. Kobayashi, K.Nakamoto, K. Yamazaki
    J. Engineering Manufacture, V223, P. 121-131
    Professional Engineering Publishing, 2009.
  3. DEVELOPMENT OF A COMPUTER ASSISTANT PROGRAMMING SYSTEM FOR MICRO/NANO MILLING TOOL FABRICATION BY MULTI-AXIS WIRE EDM
    X. Cheng, Z.G. Wang, S. Kobayashi, K.Nakamoto, K. Yamazaki
    International Journal of Computer Integrated Manufacturing. , V22, P. 847-856
    Taylor & Francis, 2009.
  4. TOOL FABRICATION SYSTEM FOR MICRO/NANO MILLING---FUNCTION ANALYSIS AND DESIGN OF A SIX-AXIS WIRE EDM MACHINE
    X. Cheng, Z.G. Wang, S. Kobayashi, K.Nakamoto, K. Yamazaki
    International Journal of Advanced Manufacturing
    DOI: 10.1007/s00170-009-2094-8, Springer, 2009.
  5. DEVELOPMENT OF ULTRA-PRECISION MACHINING SYSTEM WITH UNIQUE WIRE EDM TOOL FABRICATION SYSTEM FOR MICRO/NANO-MACHINING
    X. Cheng, K. Nakamoto, M. Sugai, S. Matsumoto, Z.G. Wang, K. Yamazaki
    CIRP Annals -Manufacturing Technology, Volume 57, Issue 1, 2008, P. 415-420
    Elsevier, 2008.

Poster

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