Electrochemical micromachining (ECM) processes use anodic dissolution of metals to remove workpiece materials. ECM processes including electrochemical milling and drilling, wire electrochemical machining and electrochemical etching offer a better alternative in manufacturing complex features and nano-pattern surface. Electrochemical discharge machining (ECDM) uses high temperature of electrochemical spark, which is suitable process for micro machining of hard brittle and non-conductive materials such as glass and ceramic. In this paper, the state of the art in electrochemical micro machining technologies was reviewed. Also, some hybrid machining methods are introduced.
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Modelling Overcut Dynamics in Electrochemical Discharge Drilling of Alumina (Al
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Study on Micro Grooving of Tungsten Carbide Using Disk Tool Min Ki Kim, Chan Young Yang, Dae Bo Sim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(2): 123. CrossRef
Machining Characteristics of Micro EDM of Silicon Carbide Ju Hyeon Lee, Chan Young Yang, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(2): 131. CrossRef
Micro Pin Fabrication of Tungsten Carbide Using Polycrystalline Diamond Joo A Park, Ui Seok Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2020; 37(11): 791. CrossRef
Effect of Vibration and Machining Area in the Fabrication of Micro Tool by Reverse EDM Yung Na, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2019; 36(2): 169. CrossRef
Energy beam machining is a type of micro/nano-manufacturing technology for advanced materials. The energy beam is composed of the matter which exhibits not only particle but also wave-like behaviors. In this paper, we focused on the energy beam machining using the charged particles, which is classified into electron beam and ion beam machining. The equipment and principles of irradiation of electron beam and ion beam are investigated, and the range of technologies according to the energy beam characteristics is summarized. For the electron beam machining, recent studies for equipment development of surface heat treatment process and electron beam melting process using low-power electron beam are summarized. For the ion beam machining, recent studies on focused ion beam machining with various materials, such as high hardness materials, optical materials and semiconductor materials, are summarized. The studies for improving the accuracy and productivity of focused ion beam machining was is summarized. It was found that numerous technologies using the energy beam have been achieved for manufacturing of micro/nano-components with high precision. It is expected that the energy beam machining becomes a promising manufacturing technology for advanced materials.
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Lightweight parts are necessary to improve fuel efficiency and reduce environmental impacts in transportation industry. As a result, there has been a shift away from using conventional metals toward using lighter materials with superior mechanical strength. These new materials typically include titanium alloys, nickel alloys, carbon fiber reinforced plastics (CFRPs), and CFRP-metal stacks, which are classified as advanced materials. However, due to the unique properties of these materials (e.g., high strength, low thermal conductivity, carbon fiber-induced hardness, etc.), the cutting process can be difficult. As a result, various manufacturing issues can occur during the cutting process, such as high tool wear, surface quality deterioration, delamination of the CFRP layer, fiber pull-out, and thermal deformation. In this paper, difficult-to-cut advanced materials were reviewed with regard to the influence of the physical properties of the materials and various defect issues that can occur during the mechanical cutting process. In addition, various approaches to improve the cutting process are introduced, including protecting tools with coatings, altering tool features, using high pressure or cryogenic cooling, extending tool life via ultrasonic vibration machining, and improving product quality and machinability.
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FEM (Finite Element Method)-based numerical analysis model, which is known as CAE (Computer Aided Engineering) technology, has been adopted for the visual/mechanical analysis of machining process. The essential models for the FEM analytical model are the plasticity model of workpieces, friction model, and wear rate model. Usually, the outputs of the FEM analytical model are the cutting force, the cutting temperature, and chip formation. Based on these outputs, the machining performance can be virtually evaluated without experiments. Nowadays, there are emerging machining technologies, such as cryogenic assisted machining and CFRP machining. Therefore, FEM technique can be one of the good candidate to virtually evaluate emerging developed machining technologies.
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As geometry of machined parts becomes complex the demands for more precise and faster machining using advanced computerized numerical control (CNC) are increased. Especially, recently improved computing power of CNC enables the implementation of the complicated control algorithms. Consequently a variety of intelligent control algorithms have been studied and implemented in CNC. This paper reviews the recent progress of control technologies for precision machining using CNC in the area of interpolation, contour control and compensation. In terms of interpolation several corner blending methods and parametric curves are introduced and the characteristics of each method are discussed. Regarding contour control algorithms recently developed multi-axis contour control methods are reviewed. Latest research efforts in compensation algorithms for geometric, thermal and friction induced errors in CNC machining are introduced.
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Monitoring technology of machining operations has a long history since unmanned machining was introduced. Lots of research papers were presented and some of them has been commercialized and applied to shop floor. Despite the long history, many researchers have presented new approaches continuously in this area. This paper presents current state of monitoring technology of machining operations. The objectives of monitoring are shortly summarized, and the monitoring methods and the unique sensor technologies are reviewed. The main objective of the monitoring technology remains same; tool condition monitoring (TCM). The general approaches also remain similar; signal processing and decision making. But, the innovative methods for every step of process monitoring are being provided to improve the performance. More powerful computing is lowering the wall of much more data from more sensors by fast calculation. This technology also introduces the novel decision making strategies such as Artificial Intelligent. New materials and new communication technologies are breaking the limitation of sensor positions. Virtual machining technology which estimates the machining physics is being integrated with monitoring technology.
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The fabrication of a micro column array using micro EDM (Electrical Discharge Machining) and eccentric tools was presented. With the eccentric tools, micro columns can be easily machined only by feeding the tool vertically, as is the case in mechanical drilling. Moreover, the tool electrode rotates very fast, which is helpful to flush dielectric fluid in the EDM. In this paper, four eccentric tools were machined, and a micro column was machined in a few minutes. Finally, a hundred micro columns with 200-300 μm in a diameter were machined on a metal plate. In this study, vibration-assisted EDM was introduced to improve the machining rate in the fabrication of eccentric tools. Also, the design parameters of eccentric tools were discussed.
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Study on Micro Grooving of Tungsten Carbide Using Disk Tool Min Ki Kim, Chan Young Yang, Dae Bo Sim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(2): 123. CrossRef
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This paper describes an adaptive model free speed control algorithm for DC motors, based on a recursive least-squares with forgetting factor. In order to control the speed of a DC motor, only the factors of output speed and voltage values have been used without a mathematical model of the DC motor. As the relationship between the input voltage and the DC motor speed in a specific region can be approximated as a first order system, the coefficient that represents the approximated first order system has been estimated by using a recursive least-squares approach with a forgetting factor model. Also, the error between the actual system and the approximated first order system has been estimated by a disturbance observer. Based on the estimated coefficient of the first order system, as well as this disturbance, an optimal input for tracking the desired velocity has been computed by using the Lyapunov direct method. Weighting factor adaptation rules have been proposed to enhance control performance. This performance evaluation has been conducted in a MATLAB/Simulink environment using a DC motor dynamic model for realistic evaluation. The evaluation results show that the developed adaptive DC motor speed control method ensures good tracking performance by using only the input voltage and the output speed information.
Polymer microlens manufacturing using thermal reflow was simulated and optimized by a numerical approach. Microlenses are used in various industrial fields, such as optical, semiconductor, and observation experiment equipment. Therefore, polymer microlens fabrication using an economical thermal reflow process is important for mass production and cost reduction. The feasibility of a thermal reflow process for microlens fabrication was analyzed in this paper by numerical methods. First, we refer to the previous studies and papers for the theoretical shape of the microlens. Second, for numerical simulation of the process above Tg (Glass Transition Temperature), we studied the multiphase flow simulation using a VOF method and adopted a Cross-WLF model to consider the rheological characteristics of PMMA. Finally, several parametric studies were carried out to compare the simulation profile and the theoretical lens shape in order to optimize the thermal reflow process. The numerical approach presented in this paper would enable a more efficient analysis and provide better understanding of reflow behavior to obtain the optimal process.
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In this paper, fatigue life of extruded aluminium single lap joints, both by self-piercing rivet (SPR) and by hybrid joining (Adhesive-SPR), were characterised based on the quasi-static and fatigue tests. The rivet tail pull-out fracture occurred in the SPR joint specimen under the quasi-static tensile test because the peel stress caused the rivet to separate from the joint. Therefore, adhesive joining was considered to effectively prevent the rivet in the joint specimen from separation. As a result, 68% higher tensile strength of the hybrid joint specimen was observed, compared to that of the SPR joint specimen. From the fatigue tests, the fatigue limit load of SPR joint specimen was found to be 4.8 kN i.e.35% of tensile strength load. The fatigue limit load of the hybrid joint specimen was revealed to be 5.6 kN, i.e., 20% of tensile strength load. Over the fatigue limit load conditions, fracture in base material was shown in the case of SPR joint specimen. Also, fractures in base material and transient failure in adhesives were observed in hybrid joint specimen.
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Recently, various attempts have been made to apply the additive manufacturing technology directly to fabricate a product. In this regards, the industry is focusing on the multi-material additive manufacturing technology that can processes multiple materials simultaneously. This study is about the fabrication of a 3-dimensional circuit device (3DCD), based on the multimaterial additive manufacturing technology, which is combination of the material extrusion and the direct writing processes. The multi-material additive manufacturing system was developed based on the commercial multi-head FDM system. In addition, a contact type nozzle for the dispensing of the conductive material in the direct writing process is proposed. The 3-dimensional circuit device in which circuit elements are arranged on several layers was fabricated successfully, based on the presented multi-material additive manufacturing system.
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This paper presents a proposed means of frequency-tuning a magnetostrictive energy harvester(EH). This end may be accomplished by decreasing the distance between two permanent magnets (PM) located at free end of the cantilever and at the opposite, resulting in increase of a repulsive force between the PMs. The EH consists of a coil-wound Galfenol cantilever with PMs, a mover connected to the cantilever, and a rotating wheel with PMs. The rotating wheel driven by a motor provides a forced vibration to the EH. To direct inspection, It is noted that the maximum output voltage continually changes depending upon the the distance between the PMs And itmight therefore be deduced that the resonant frequency of the harvester may be adjusted to attain maximum, or optimal, voltage output. The rotational speed of the wheel (for the purpose of attaining maximum output voltage) is changed from 325 rpm to 265 rpm at a distance of 10 mm. It can be concluded that the practice of frequency-tuning with two PMs is a potentially positive application with respect to the EH.
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