Micro-Manufacturing Technologies and Their Applications (eBook)

A Theoretical and Practical Guide

Irene Fassi, David Shipley (Herausgeber)

eBook Download: PDF

2017 | 1st ed. 2017
XII, 296 Seiten
Springer International Publishing (Verlag)
978-3-319-39651-4 (ISBN)

Infos

This book provides in-depth theoretical and practical information on recent advances in micro-manufacturing technologies and processes, covering such topics as micro-injection moulding, micro-cutting, micro-EDM, micro-assembly, micro-additive manufacturing, moulded interconnected devices, and microscale metrology. It is designed to provide complementary material for the related e-learning platform on micro-manufacturing developed within the framework of the Leonardo da Vinci project 2013-3748/542424: MIMAN-T: Micro-Manufacturing Training System for SMEs. The book is mainly addressed to technicians and prospective professionals in the sector and will serve as an easily usable tool to facilitate the translation of micro-manufacturing technologies into tangible industrial benefits. Numerous examples are included to assist readers in learning and implementing the described technologies. In addition, an individual chapter is devoted to technological foresight, addressing market analysis and business models for micro-manufacturers.

Inhalt

Preface 6
Contents 7
Acronyms 8
1 Introduction to Miniaturisation 12
1.1 Introduction 12
1.2 Scaling Laws 13
1.2.1 Geometry 14
1.2.2 Mechanics 14
1.2.3 Dynamics 15
1.2.4 Micro-fluidics 16
1.2.5 Van der Waals Force 18
1.2.6 Electromagnetism 19
1.2.7 Thermodynamics 20
1.2.8 Scaling with Distances 20
1.2.9 Scaling Exponent 22
1.3 Materials 22
1.3.1 Smart Materials 24
1.3.1.1 Piezoelectric Materials 24
1.3.1.2 Shape Memory Alloy 25
1.3.1.3 Electroactive Polymers 26
1.4 Micro-factories 28
References 32
2 Micro-injection Moulding 34
2.1 Overview 34
2.1.1 Technical Description 34
2.1.2 Definition of Technology 35
2.2 Materials 37
2.3 Design and Simulation 38
2.3.1 Characterisation—Micro-rheology 38
2.3.2 Rheological Simulation 38
2.3.3 Conclusions 39
2.4 Process and Materials 41
2.4.1 Principles of the Injection Moulding Process 41
2.4.2 Key Features 44
2.4.3 Dosage (Charge) 44
2.4.4 Injection Speed 46
2.4.5 Injection Pressure 46
2.4.6 Holding Pressure 47
2.4.7 Holding Pressure Time 47
2.4.8 Cooling Time 48
2.4.9 Process Temperatures in the Mould, Expansion and Balance 48
2.4.10 Mould Venting 50
2.5 Tools and Machines 53
2.5.1 The Injection Machine 53
2.5.2 Plasticising Systems 56
2.5.3 Micro-injection System Without Plasticising 58
2.5.4 Main Micro-injection Moulding Machines 59
2.5.5 Micro-injection Moulds 59
2.6 Sectors of Application 63
2.7 Handling and Verification of Micro-parts 67
2.7.1 Handling 67
2.7.2 Inspection 68
2.7.3 Morphological Analysis 69
2.7.4 Mechanical Analysis 70
2.8 Application Case: Micro-filter 71
2.8.1 Description 71
2.8.2 Micro-filter Design Analysis (FEM/CAE) 73
2.8.3 Micro-injection Process Simulation 73
2.8.3.1 Filling and Parameters 73
2.8.3.2 Gate Positioning Optimisation 73
2.8.3.3 Welding Lines and Air Traps Analysis 75
2.8.4 Mould Design and Manufacturing 75
2.9 Process Optimisation and Part Production 76
Bibliography 77
3 Micro-additive Manufacturing Technology 78
3.1 Overview 78
3.2 Micro-stereolithography (MSL) and Two Photon Polymerisation (2PP) 80
3.2.1 Operating Principles 80
3.2.2 Technology Overview and Systems 82
3.2.3 Materials 84
3.2.4 Applications 85
3.3 Powder Bed Fusion Technologies 87
3.3.1 Operating Principles 87
3.3.2 Technology Overview and Systems 88
3.3.3 Machines and Materials 88
3.3.4 Applications (Table 3.3) 90
3.4 Three Dimensional Printing via Binder Jetting 91
3.4.1 Operating Principles 92
3.4.2 Technology Overview and Systems 93
3.4.3 Machines and Materials 94
3.4.4 Applications 95
3.5 Three Dimensional Printing via Material Jetting 95
3.5.1 Operating Principles 95
3.5.2 Technology Overview and Systems 96
3.5.3 Machines and Materials 97
3.5.4 Materials 98
3.5.5 Applications 99
3.6 Filament Deposition 100
3.6.1 Operating Principles 100
3.6.2 Technology Overview and Systems 101
3.6.3 Machines and Materials 102
3.6.4 Applications 105
References 105
4 Manufacturing Technology: Micro-machining 107
4.1 Overview 107
4.1.1 Why Micro-machining? 107
4.1.2 Definitions 108
4.1.2.1 Micro-cutting 108
4.1.2.2 Size Effect 109
4.1.2.3 Uncut Chip Thickness 110
4.1.2.4 Rake Angle 110
4.1.2.5 Shearing, Ploughing, and Rubbing 110
4.2 Engineering Materials and Material Properties 110
4.2.1 Elastic and Plastic Material Behaviour 110
4.2.2 Failure of Materials 112
4.2.2.1 Crack Propagation 113
4.3 Design and Simulation 114
4.3.1 Introduction 114
4.3.2 Why Simulate Micro-cutting? 114
4.3.2.1 Micro-machining Simulation 115
4.3.2.2 Machining Strategies 116
4.3.3 Micro Versus Conventional Machining 116
4.3.4 Issues Covered by Modelling of Micro-machining 117
4.3.5 Mechanistic Modelling of the Micro-cutting Process 118
4.3.6 Finite Element Analysis (FEA) 119
4.3.6.1 Established Predictive FEA Models 119
4.3.7 Molecular Dynamics Modelling Approach 120
4.3.7.1 Established MD Models 120
4.3.8 Multi-scale Simulation Methods 120
4.3.9 Indicative Costs 121
4.4 Process, Tools and Machines 121
4.4.1 Process 121
4.4.1.1 Machining Scale 122
4.4.1.2 Cutting Forces 123
4.4.1.3 Size Effect 125
4.4.1.4 Burr Formation 125
4.4.2 Micro-tools 126
4.4.2.1 Tool Size 126
4.4.2.2 Tool Wear and Breakage 127
4.4.2.3 Micro-tool Coatings 129
4.4.3 Machine-Tools 129
4.4.3.1 Micro-machining Platform Characteristics 129
4.4.3.2 Machine-Tools Suppliers 130
4.4.4 Measurement Systems 132
4.4.4.1 Geometric Measurement: Pre-processing 132
4.4.4.2 Geometric Measurement: During Processing 132
4.4.4.3 Geometric Measurement: Post-processing 133
4.4.4.4 Process Parameters Measurement 134
4.5 Sectors and Applications 135
4.5.1 Industry Sectors and Application Areas 135
References 136
5 Micro-waterjet Technology 138
5.1 Introduction to Waterjet Technology 138
5.2 High Energy Fluid Jet Generation 139
5.2.1 High Pressure Pump 139
5.2.2 High Pressure Circuit 140
5.2.3 Handling System and Fixturing 141
5.2.4 Energy Conversion 141
5.2.5 Machining Mechanism and Cutting Heads 142
5.2.6 Abrasive Feeding System 143
5.2.7 Catcher 144
5.3 AWJ Quality Assessment 144
5.3.1 Machining Defects Description 146
5.3.2 Defect Reduction Methods 146
5.4 Micro-AWJ Technology 149
5.5 Micro-AWJ Key Features 149
5.5.1 Micro-AWJ Enabling Characteristics 150
5.6 Micro-AWJ Case Studies 151
5.6.1 Precision Through Defect Compensation 151
5.6.2 Thin Layers Drilling 152
5.6.3 Inhomogeneous Materials 153
5.6.4 Advanced Alloys for Biomedical Applications 154
5.6.5 Thin Details Cutting on POM 155
5.6.6 Stainless Steel Racks Small Batch 155
5.6.7 Deep Holes with Tight Tolerances 155
References 157
6 Micro-electro-Discharge Machining (Micro-EDM) 158
6.1 Principle of Electro-Discharge Machining (EDM) 158
6.2 Micro-EDM Process Parameters 161
6.3 Performance of the Micro-EDM Process: Quality Indices 163
6.3.1 Micro-EDM Milling Optimisation via Design of Experiments (DoE) 165
6.3.2 Monitoring for Evaluating Micro-EDM Performance 166
6.3.3 Tool Wear and Tool Path: How to Obtain Surface and Profile Accuracy in Micro-EDM Features 167
6.3.4 High Aspect Ratio Cavities: Role of Tool Wear and Dielectric Flushing 169
6.4 Materials and Effects on Micro-EDM Process 170
6.5 Applications 171
6.5.1 Straight Bevel Micro-gear 171
6.5.2 Customised Internal Fixation Devices for Orthopaedic Surgery 173
6.5.3 Micro-EDM Milling/Sinking Combined Approaches: Micro-filter Mould 177
References 180
7 Moulded Interconnect Devices 183
7.1 Overview—Moulded Interconnect Devices 183
7.2 Materials 185
7.2.1 Introduction 185
7.2.2 Requirement for Substrate Material 186
7.2.3 Typical MID Materials 187
7.3 Processes 188
7.3.1 Overview 188
7.3.2 Two-Shot Injection Moulding 188
7.3.3 Laser Direct Structuring (LDS) 191
7.3.4 Hot Embossing 194
7.3.5 Aerosol-Jet Printing 195
7.3.6 Advantages and Challenges of Each Technology 197
7.4 MID Assembly 199
7.4.1 Mounting Techniques 199
7.4.2 Positioning 199
7.4.3 Challenges 200
7.5 Sectors and Applications 201
7.6 Application Case 202
References 203
8 Micro-scale Geometry Measurement 205
8.1 Introduction 205
8.2 Contact Techniques 206
8.2.1 Stylus Instruments 206
8.2.2 Micro Coordinate Measuring Machines 207
8.2.2.1 Introduction to Coordinate Measuring Machines 207
8.2.2.2 Capability of Commercial Micro-CMMs 208
8.2.2.3 Micro-probing Systems 208
8.2.2.4 Sources of Error on CMMs 211
8.3 Non-contact Techniques 212
8.3.1 Focus Variation Microscopy 212
8.3.2 Coherence Scanning Interferometry 213
8.3.3 Confocal Microscopy 215
8.3.4 Laser Triangulation 217
8.3.5 Micro-fringe Projection 219
8.4 Tomographic Methods 220
8.4.1 Optical Coherence Tomography 220
8.4.2 X-ray Computed Tomography 223
References 224
9 Micro-assembly 230
9.1 Introduction 230
9.2 Hybrid Micro-systems Production 231
9.3 Micro-assembly Definition 231
9.4 Micro-assembly Methods 233
9.4.1 Classification 233
9.4.2 Robotic Micro-assembly 236
9.4.3 Self-assembly 237
9.4.4 Robotic Micro-assembly and Self-assembly Compared 237
9.4.5 Hybrid Micro-assembly 238
9.5 Robots for Micro-assembly 239
9.5.1 Definition 239
9.5.2 Classification 240
9.5.3 Design Considerations 241
9.5.4 Example of Robots for Micro-assembly 242
9.6 Micro-manipulation Systems 245
9.6.1 Issues in Micro-manipulation 245
9.6.2 Micro-manipulation Strategies 246
9.6.2.1 Contact Manipulation 246
9.6.2.2 Contact-Free Handling 249
9.6.3 Release Strategies 250
9.6.3.1 Active Techniques 250
9.6.3.2 Passive Techniques 251
9.7 Sensors and Control Methods for Micro-assembly 251
9.7.1 Vision 251
9.7.2 Force Sensing 255
9.7.3 Environmental Conditioning in Micro-assembly 256
9.8 A Case Study: The ITIA Micro-assembly Work-Cell 258
References 261
10 Market Analysis, Technological Foresight, and Business Models for Micro-manufacturing 267
10.1 Introduction 267
10.2 Micro-manufacturing Market Analysis 268
10.2.1 Business Drivers and Market Demands 268
10.2.2 Main Sectors of Application 269
10.2.2.1 Healthcare 271
10.2.2.2 Energy 271
10.2.2.3 Aerospace 272
10.2.3 Key Stakeholders 273
10.2.4 Strengths, Weaknesses, Opportunities, Threats 274
10.3 Future of Micro-manufacturing Market and Technological Foresighting 276
10.3.1 Market Trends 276
10.3.2 Future Sectors 277
10.3.3 Future Applications and Technologies 278
10.3.3.1 Future of Micro-parts 279
10.3.3.2 Future of Micro-manufacturing Technologies 281
10.4 Business Models for Micro-manufacturing 282
10.4.1 What Is a Business Model? 282
10.4.1.1 Business Model Elements 283
10.4.2 Innovative Business Models 286
10.4.3 Current Business Models for Micro-manufacturing 287
10.4.3.1 Traditional Machinery Selling 287
10.4.3.2 Production Service 288
10.4.4 Innovative Business Models for Micro-manufacturing 290
10.4.4.1 Personalised Manufacturing for Healthcare with Closed Integration with Hospitals 290
10.4.4.2 Micro-factory 292
10.4.4.3 Micro-machinery Producers 293
References 296
Index 298

Produkt-Details

• Erscheint lt. Verlag: 31.1.2017
• Reihe/Serie: Springer Tracts in Mechanical Engineering
• Reihe/Serie: Springer Tracts in Mechanical Engineering
• Zusatzinfo: XII, 296 p. 192 illus., 11 illus. in color.
• Verlagsort: Cham
• Sprache: englisch
• Themenwelt: Technik ► Maschinenbau
• Schlagworte: Additive Manufacturing • microassembly • Micro EDM • Microinjection Moulding • Micromachining • Micromanufacturing Processes • Micro-Manufacturing Technologies • MIMAN-T • Moulded Interconnected Devices
• ISBN-10: 3-319-39651-X / 331939651X
• ISBN-13: 978-3-319-39651-4 / 9783319396514