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International Journal of Precision Technology (3 papers in press)
Computer aided tool design for micro-ECM by Pratik Shah, S.S. Pande Abstract: This paper reports the development of a computer aided system for micro-ECM process to design tools to produce accurate internal features on workpiece. Mathematical model has been developed to compute the inter-electrode gap (IEG) for chosen shape of tool and process conditions. Axi-symmetric tools of different profiles such as cylindrical, conical, hemispherical have been analyzed to predict the shapes of work cavities. Model is validated with the reported results and some experiments conducted by us on typical tool shapes. Parametric studies have been carried out to study influence of various process variables on the accuracy of cavity shapes. Based on these studies, guidelines for improving profile accuracy in micro-ECM have been suggested. Keywords: Micro-ECM; computer aided design system; inter-electrode gap; tool design; process model; parametric studies.
Carbon Nanofiber (CNF) Assisted Micro-Electro Discharge Machining ( by Prasanna Chougule, Rakesh Mote, Uday Dabade Abstract: Titanium alloys have found growing applications in aerospace, biomedical and marine industry. However, extreme hardness and strength cause difficulty in machining of titanium alloys. This is further complicated by the requirements of micro features on hard to machine alloys. Micro Electro discharge machining (micro EDM) is being investigated to match the requirement. However, slower removal rates and thermal effects are the issues in thermal erosion based EDM process. In this work, we have investigated the efficacy of using carbon nanofibers (CNFs) mixed with the dielectric fluid for micro machining of Ti6Al4V using micro EDM. It is observed that the addition of CNFs not only improves electro-discharge frequency, material removal rate but also improves the surface roughness. Added nanofibers lowered the material migration and increased spark gap. We noted a significant influence of mixing CNFs in the dielectric fluid for enhancing machining performance characteristics in Keywords: Micromachining; Micro-EDM; Titanium alloys; Carbon nanofibers (CNFs); Additives; Surface integrity.
Micro-Faraday cup array structures fabrication in Silicon using Deep Reactive Ion Etching by JULFEKAR ARAB, Pradeep Dixit, Prakash Brahmankar, Raju Pawade, Arvind Kumar Srivastava Abstract: Micro-faraday cup array (MFCA) detectors are used for the detection and analysis of incident ion particles. Over the years, MFCA played the vital role in the field ion detection with greater stability and precision. New and simple Micro FCA structures have been designed and fabricated considering the application of ion detection in devices such as Mass spectrometry and laser plasma techniques. MFCA structures were fabricated in n-type Silicon substrate with MEMS fabrication processes such as UV lithography followed by DRIE (Deep reactive ion etching). The UV lithography process was utilized for fabrication of Micro-Faraday cup array structure in photoresist (AZ4903) deposited on silicon substrate. After that DRIE process was used for creating array pattern in Silicon. Ultimately 1x16 arrays having 25 Keywords: Faraday Cups; micro-fabrication; characterization; UV-LED; DRIE.