4M Knowledge base - papers

A. Herrero(a), J. Esmoris(a), S. Azcarate(a), S. Geissdoerfer(b), U. Engel(b)
a: Department of Micro & Nano Technologies, Tekniker, Avda. Otaola 20, 20600 Eibar, Spain
b: Universität Erlangen-Nürnberg, Egerlandstrasse 11, 91058 Erlangen, Germany

Abstract

The mass production of micro and meso scale products made of polymers or metals is intimately related to the production of high quality microtooling in stable materials capable to provide an accurate and repetitive performance throughout the whole demanded production. As it is widely known, the WEDM process provides high accuracy but is conceptually limited to the production of ruled features. The SEDM process can be a complement to this aspect but the electrodes must be manufactured by other technologies like WEDM, micromilling, turning, etc. Given the importance of several parameters like dimensional accuracy, tooling material for the different replication processes or tooling production technology, the present paper introduces some tests performed by the 4M Metals Workgroup. The analysis of some components manufactured by members of the group is presented discussing the influence of the EDM process on the machined tooling components and the consequent influence on the replication process.

M. Zimmermann, L. Schaefer, M. Rank, M. Schmidt, S. Roth
Bayerisches Laserzentrum gGmbH, Konrad-Zuse-Str. 2-6, 91052 Erlangen, Germany

Abstract

The proceeding integration and miniaturization of mechanical and optical functions in systems for optical communication, for sensor and environmental technologies or for life sciences require an improvement and a customization of the manufacturing technologies. For fiber optical systems and components, especially for singlemode applications, adequate methods for a precise adjustment are necessary which allow a fast and cost-efficient alignment of fibers and other optical components like microlenses or laserdiodes. The demands on the adjustment process rise additionally for array applications. Laser based micro alignment is a promising technology for such critical adjustment tasks. We investigated the use of this technology for the alignment of fibers within fiber arrays. They are used for the assembly of fiber collimator arrays. We developed and analysed suitable actuator geometries for this application. In this paper we show some important results of the FEM based analyses to demonstrate the influence of the laser irradiation regime. First experimental results confirm the actuator behaviour calculated in the FEM analysis. Based on the simulations and experimental results, we are developing a compact alignment module which is adapted to the demands on the assembly process of fiber optical components. This alignment tool is one module within a complete miniaturised, scaleable and modular assembly line for the production of fiber collimator arrays.

C. P-Withen (a), J. R. Marstrand (a), M. Arentoft (b), N. A. Paldan (b)
a Department of Manufacturing Engineering and Management, Technical University of Denmark, Produktionstorvet, Building 427, DK- 2800 Kgs. Lyngby, Denmark
b Institute for Product Development, Produktionstorvet, Building 425, DK- 2800 Kgs. Lyngby, Denmark

Abstract

The advantages of cold forging micro-components are the same as for conventional cold forging, namely the high production rate and the low material waste. To achieve this, a flexible tool system for cold forging of micro-components has been developed. When transferring the technique of cold forging from macro- to micro-scale, size effect and change in friction are conditions that have to be considered. Furthermore the precision of the tool system is crucial owing to the low tolerances on the dimensions of micro-components.

The tool system is designed for the eight basic cold forging processes with some replaceable process dependent parts. Furthermore it is possible to replace critical parts to reduce expenses if tool breakdown occurs. The system is tested by forging of an industrial component. The tool system is produced by micro-EDM and high precision machining.

The test of the final tool system shows that it can be used to cold forge micro-components. An Ø0.8mm rod is extruded 0.9mm to Ø0.3mm in an Ag97Cu3 alloy. The geometry of the cold forged component is close to the specified geometry. This indicates that the component can be cold forged with a few adjustments of the die and punch geometries. The ejection of the cold forged component proved difficult and a slight bend of the extruded part occurred.

N. Boudeaua (b), S. Thibauda (b), J.F. Michel (a)
a Department LMARC, FEMTO-ST Institute, 25000 Besançon, France
b ENSMM, 25030 Besançon cedex, France

Abstract

Optimizing productivity, parts quality, reducing production costs are objectives that companies must perpetually satisfy to remain competitive. An efficient solution, but complex to implement, consists in modifying completely the manufacturing process. That is the goal of these research works : it consists in manufacturing micro-electronic components by deep drawing which are currently rolled and welded leading to a strong rate of reject.

The objective of this work is to study the feasibility of skirts of Molybdenum Rhenium cathodes by micro-stamping. First, various nuances of Molybdenum Rhenium to low thickness (< 100 μm) have been characterized in their (large) plastic range of deformation.

Secondly, a forming process leading to no folds and no tears has been defined by means of finite element simulations.

Finally, a modular micro-stamping tool has been developed ; it includes the blanking process and the forming procedures. The different forming stages are determined from numerical simulations. The two first stages have been investigated experimentally and are presented.