4M Knowledge base - papers

G. Tosello(a), B. Fillon(b), S. Azcarate(c), A. Schoth(d), L. Mattsson(e), C. Griffiths(f), L. Staemmler(g), P.J. Bolt(h)
a: Technical University of Denmark (DTU), Department of Manufacturing Engineering and Management (IPL), 2800 Kgs. Lyngby, Denmark
b: French Atomic Energy Commission (CEA), Laboratory of Innovation for New Energy Technologies and Nanomaterials (LITEN), 38054 Grenoble, France
c: Tekniker Technological Center, 20600 Eibar, Spain
d: University of Freiburg, Institute of Microsystem Technology (IMTEK), 79110 Freiburg, Germany
e: School of Industrial Technology and Management (KTH), Department of Production Engineering, 100 44 Stockholm, Sweden
f: Cardiff University, Manufacturing Engineering Center (MEC), Cardiff CF 24 3AA, UK
g: Hahn-Schickard-Gesellschaft, Institute for Micro Assembly Technology (HSG-IMAT), 70174 Stuttgart, Germany
h: TNO Science & Industry, 5600 HE Eindhoven, The Nederlands

Abstract

This paper is based on the Division 4 “Processing of Polymers” activities within the 4M NoE “Multi-Material Micro Manufacturing”. To overpass limitations of the current existing micro tooling capabilities, a new generation of micro hybrid tooling technologies for micro replication was developed. A metrological approach was applied to standardize the employed tooling processes (μ-milling, μ-EDM, laser μ-machining, electrochemical μ-milling). The micro tools were then tested with different polymers. The paper provides a comparison of these technologies concerning obtainable feature sizes, surface finishing, and aspect ratios of both micro tools and micro moulded parts.

C. Brecher(a)(b), R. Klar(b), C. Wenzel(b)
a: Werkzeugmaschinenlabor (WZL), RWTH Aachen University, Aachen, Germany
b: Fraunhofer-Institute for Production Technology, Aachen, Germany

Abstract

One of the main focuses in many research fields is the miniaturisation of work pieces and components. Micro fluidic, micro mechanic, micro electronic and micro optical functional groups are integrated into smallest space to microsystems for medical, information technology or automotive purposes. Directly opposed to the miniaturisation trend of these products are the machine tools used for the production becoming bigger and bigger, with the result that the proportion between the machining space and the needed floor space is more and more inefficient. To meet the process requirements as well as the requirements of the machine users of flexible and small high performance machine tools the Fraunhofer IPT developed and designed a compact high precision milling machine. The paper describes current trends in the field of compact machine tools under special consideration of the mechanical setup and the development of a small and high precise as well as high dynamic micro milling machine.

Chantal Khan Maleka, Gaël Thuilliera, Roland Duffaitb , Laurent Guyoutc
a Laboratoire FEMTO-ST, CNRS UMR 6174, Département LPMO, 32 Avenue de l’Observatoire, 25044 Besançon Cedex, France.
b Centre de Transfert des Micro et Nanotechnologies (CTMN), 39 Avenue de l’Observatoire, BP 1445-25007 Besançon Cedex 3, France.
c Department of Applied Mechanical Engineering, University of Franche Comté, 16 Route de Gray, 25030 Besançon Cedex, France.

Abstract

Our approach uses a two-step replication process for hot embossing and a rigid polymeric intermediate mould. This process overcomes some geometrical limitations in microstructured mould fabrication, enables positive-tone imprinting, prolongs the lifetime of the master, and lowers the overall cost of the replication process.

Th. Gietzelt(a), L. Eichhorn(a), J. Binder(b)
a: Institute of Micro Process Engineering, Forschungszentrum Karlsruhe, P.O. Box 3640, 76021 Karlsruhe, Germany
b: Institute of Material Research III, Forschungszentrum Karlsruhe, P.O. Box 3640, 76021 Karlsruhe, Germany

Abstract

Micromachining is a very flexible and universal technique, compared to EDM (electrical discharge machining) or ECM (electrochemical machining). There are nearly no limitations in design. Also 3D-structures can be easily machined. The material removal rate is high and surface roughness in the submicron range can be obtained.

With micromilling in contrast to EDM not only electrically conductive materials but a wide range of materials like polymers, metals and alloys as well as some sorts of ceramics can be microstructured. Manufacturing of microstructures made of several kinds of ceramics with different processing routes exhibiting specific advantages and disadvantages are discussed in this paper.

K. Popov(a), S. Dimov(a), A. Ivanov(a), D. T. Pham(a), E. Gandarias(b)
a: Manufacturing Engineering Centre, Cardiff University, Cardiff CF24 3AA, UK
b: Mondragon Goi Eskola Politeknikoa, Mondragon Unibertsitatea, Loramendi 4, 20500 Arrasate, Spain

Abstract

A major issue in micro milling is the setting up of the origins of the Machine Working Coordinate Systems (MWCS). The existing methods for carrying out this operation have an unacceptably high error along the Z axis, due to the spindle thermal enlargement, and are effective only when the machining is “relative” to other surfaces milled with one cutting tool within one operation. Therefore, more efficient technical solutions are required for setting up MWCS and to reduce further uncertainties associated with micro-milling operations.

This paper describes a new cost-effective method for setting up MWCS that applies a new technical solution for detecting the contact between the cutting tool and the workpiece. A prototype system was used to validate experimentally the accuracy and repeatability of the proposed method. The results obtained showed that the sensitivity of the system is sufficient to detect accurately the contact between the cutting tool and the workpiece, and thus to set up the MWCS origins. It was concluded that by applying this method it would be possible to minimise uncertainties introduced by the spindle thermal enlargement and touch probe run-outs in setting up micro machining operations. Also, the tests undertaken showed that the prototype system is reliable and convenient for use by machine operators.