Noble tool based micromilling for nanometric surface finish

This research introduced micro electro discharge (ED) milling as a potential technique to fabricate miniaturized components. It investigated the influence of three micro ED milling process parameters, which were feed rate, capacitance and voltage. The response variables were average surface roughnes...

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Main Author:	Ali, Mohammad Yeakub
Format:	Monograph
Language:	English
Published:	Ministry of Higher Education, Malaysia 2011
Subjects:	TJ Mechanical engineering and machinery TS Manufactures
Online Access:	http://irep.iium.edu.my/28920/ http://irep.iium.edu.my/28920/1/094_FRGS_0207-44_2011_Full_Version_of_Research_Report.pdf

id	iium-28920
recordtype	eprints
spelling	iium-289202013-10-07T06:14:09Z http://irep.iium.edu.my/28920/ Noble tool based micromilling for nanometric surface finish Ali, Mohammad Yeakub TJ Mechanical engineering and machinery TS Manufactures This research introduced micro electro discharge (ED) milling as a potential technique to fabricate miniaturized components. It investigated the influence of three micro ED milling process parameters, which were feed rate, capacitance and voltage. The response variables were average surface roughness (Ra), maximum peak-to-valley roughness height (Ry), tool wear ratio (TWR) and material removal rate (MRR). Tungsten was used as the tool-electrode while beryllium-copper (Be-Cu) alloy was the workpiece. Statistical models of these output responses were developed using three-level full factorial design of experiment. The developed models were used for multiple response optimization by desirability function approach to obtain minimum Ra, Ry, TWR and maximum MRR. Maximum desirability of 88% was obtained. The optimized values were experimentally verified. The optimized values of Ra, Ry, TWR and MRR were 0.04 μm, 0.34 μm, 0.044 and 0.08 mg/min respectively, which were obtained at feed rate of 4.79 μm/s, capacitance of 0.10 nF and voltage of 80 volts. Using these process parameters, a micro swiss-roll combustor mold cavity of Be-Cu alloy was fabricated. This mold cavity can be used for mass replication by micro hot embossing or microinjection molding, which is economical compared to conventional fabrication techniques. The nano level surface finish shows the technical competency of micro ED milling over other fabrication techniques such as laser micromachining, micromilling, etc. Ministry of Higher Education, Malaysia 2011-02 Monograph NonPeerReviewed application/pdf en http://irep.iium.edu.my/28920/1/094_FRGS_0207-44_2011_Full_Version_of_Research_Report.pdf Ali, Mohammad Yeakub (2011) Noble tool based micromilling for nanometric surface finish. Research Report. Ministry of Higher Education, Malaysia, Kuala Lumpur. (Unpublished)
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English
topic	TJ Mechanical engineering and machinery TS Manufactures
spellingShingle	TJ Mechanical engineering and machinery TS Manufactures Ali, Mohammad Yeakub Noble tool based micromilling for nanometric surface finish
description	This research introduced micro electro discharge (ED) milling as a potential technique to fabricate miniaturized components. It investigated the influence of three micro ED milling process parameters, which were feed rate, capacitance and voltage. The response variables were average surface roughness (Ra), maximum peak-to-valley roughness height (Ry), tool wear ratio (TWR) and material removal rate (MRR). Tungsten was used as the tool-electrode while beryllium-copper (Be-Cu) alloy was the workpiece. Statistical models of these output responses were developed using three-level full factorial design of experiment. The developed models were used for multiple response optimization by desirability function approach to obtain minimum Ra, Ry, TWR and maximum MRR. Maximum desirability of 88% was obtained. The optimized values were experimentally verified. The optimized values of Ra, Ry, TWR and MRR were 0.04 μm, 0.34 μm, 0.044 and 0.08 mg/min respectively, which were obtained at feed rate of 4.79 μm/s, capacitance of 0.10 nF and voltage of 80 volts. Using these process parameters, a micro swiss-roll combustor mold cavity of Be-Cu alloy was fabricated. This mold cavity can be used for mass replication by micro hot embossing or microinjection molding, which is economical compared to conventional fabrication techniques. The nano level surface finish shows the technical competency of micro ED milling over other fabrication techniques such as laser micromachining, micromilling, etc.
format	Monograph
author	Ali, Mohammad Yeakub
author_facet	Ali, Mohammad Yeakub
author_sort	Ali, Mohammad Yeakub
title	Noble tool based micromilling for nanometric surface finish
title_short	Noble tool based micromilling for nanometric surface finish
title_full	Noble tool based micromilling for nanometric surface finish
title_fullStr	Noble tool based micromilling for nanometric surface finish
title_full_unstemmed	Noble tool based micromilling for nanometric surface finish
title_sort	noble tool based micromilling for nanometric surface finish
publisher	Ministry of Higher Education, Malaysia
publishDate	2011
url	http://irep.iium.edu.my/28920/ http://irep.iium.edu.my/28920/1/094_FRGS_0207-44_2011_Full_Version_of_Research_Report.pdf
first_indexed	2023-09-18T20:42:29Z
last_indexed	2023-09-18T20:42:29Z
_version_	1777409457367547904

Noble tool based micromilling for nanometric surface finish

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