Vjti A Suri

17th Feb’2009

Modern Trends in Machining & Materials, VJTI Mumbai

MICRO ENGINEERING

Aseem Suri Sinergy Nano Systems Mumbai- India

SINERGY NANO SYSTEMS     

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Sinergy Nano Systems was formed in 2005. Started as the representative of foreign companies here in India. Initiated the activity of giving consultancy for developing a manufacturing lab in 2006. Provided R&D support for developing flexure for Moon mission. SnS developed the prototype of 60Ghz waveguide multiplexers for ISRO-SAC in 2007. We are the only company which has the capability to develop such accuracy jobs here in India. Developed the capability of making micro hole arrays-2008 Currently we are emerging as a Special Purpose Machine Manufacturer and Lab machine facilities.

NANOTECHNOLOGY

Nanotechnology, the science of manipulating structures in nanometer regime is the science of today.  Carbon nano tubes, nano coatings, carbon nano rods, quantum dots, self assembled monolayer, nano drug delivery are some major areas under exploration. 

ROAD TO NANOTECHNOLOGY There are two distinct approaches to develop and deploy nanotechnology:  Bottom up approach Where in atom by atom or molecule by molecule structures are built up. This is the approach taken by scientists and is popular technique deploying chemistry, physics and pharmaceutical practices. 

Top down approach This is the engineering approach; it takes the route from micro domain to nano regime. Micro systems, MEMS, micro sensors and a host of other disciplines like micro-fluidics and micro robotics are being developed. These “Micro Systems” are bridge between real word and nanotechnology.

WHY MICRO MACHINING? Nanotechnology is fast spreading across all the branches of science and engineering.  The route to nanotechnology in machining and manufacturing field is through micro technology.  High precision engineering practices leading to micro technology are the basic building blocks for products like IC'S, MEMS, Computers, CD's, Cell phones on one hand and lasers, satellites and aerospace systems on the other.  This technology is at nascent stage of development in India. 

ENTRY INTO MICRO WORLD

World’s First •Integrated •Multi-Process •Micro Machining Tool Resolution of 0.1 micron

MULTI PROCESSES

Micro Micro Micro Micro Micro Micro

- EDM – ECM – Wire EDM - Turning - Milling - Drilling

ADVANTAGES OF INTEGRATED MULTI-PROCESS MACHINING

Electrode used in EDM & ECM can be fabricated on the same machine. Inaccuracies due to clamping & transfer can be minimized.

MICRO TURNED SAMPLES

SnS

FABRICATION OF MICRO HOLES

MICRO MACHINING CAPABILITIES1 Micro-Turning Shafts of 30 microns in diameter up to an aspect ratio of 200 by micro-turning.

Micro-Milling 70-micron fins.

Micro-Milling 100-micron slots via micromilling.

MICRO MACHINING CAPABILITIES2

Micro-EDM 30-micron shafts and 50micron holes produced by micro-EDM.

Micro-Wire Cut EDM Slots of 50 microns in width produced by wire-cut EDM.

POTENTIAL MICRO MACHINING APPLICATION AREAS

TABLE TOP DIAMOND TURNING MACHINE

MIRROR FINISHED PRODUCTS

ELID (ELECTROLYTIC IN-PROCESS DRESSING) GRINDING

ELID GRINDING OF SILICON WAFER 3NM

ELID GRINDING FOR THE MACHINING OF OPTICAL GLASS (BK7)

EFFECT OF ELID

FLEXURE FOR LENS ASSEMBLY- 1

FLEXURE FOR LENS ASSEMBLY- 2

AIRCRAFT PARTS

FILTER DESIGN

WAVE GUIDE

REFERENCE CRACKS FOR THE CALIBRATION (THICKNESS 0.15MM)

TRIANGULAR SHAFT - SILICON

MACHINE BUILDING 

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We are targeting educational institutes and are working towards building table top machines at affordable cost for colleges and institutes. We propose to build model based accuracy machine with the same structure. Currently focusing on 1 micron and 0.1 micron resolution with +/-10 and +/-3 micron accuracy respectively. We will help institutes in    

Process development. Tooling design. Fixture design. Software generation.

MACHINE BUILDING Provide consultancy for setting up of the state of the art micro engineering labs with conventional, unconventional and measurement facility.  Our future goal is to get into Special Purpose Machines.  For the educational college machines we are currently looking for institute partnerships to take up this activity in and around their respective areas. 

ELECTRICAL DISCHARGE MACHINE

Electrical discharge machining (EDM) removes metal by discharging electric current from a pulsating DC power supply across a thin inter-electrode gap. The gap is filled by a dielectric fluid.

EXAMPLES OF EDM Stepped cavities produced with a square electrode by the EDM process. The work piece moves in the two principal horizontal directions (x-y), and its motion is synchronized with the downward movement of the electrode to produce these cavities. Also shown is a round electrode capable of producing round or elliptical cavities.

Schematic illustration of producing an inner cavity by EDM, using a specially designed electrode with a hinged tip, which is slowly opened and rotated to produce the

SPIRAL CAVITY

A spiral cavity produced by EDM using a slowly rotating electrode, similar to a screw thread

WIRE EDM

• Wire materials: Brass, Copper, Tungsten, Zinc or Brass coated wires. •Diameter: typically 0.3mm fro roughing cuts and 0.20 mm for finishing cuts.

WIRE EDM

Cutting a thick plate with wire EDM

WIRE EDM PARTS

PROPOSED SPECIAL EDM MACHINE     

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Table top miniature EDM machine. Granite base size: 300mm x 300mm x 80mm Total height: 500mm (approximately) Resolution: 1µm EDM Power: Hybrid type (Transistor Pulse + RC relaxation) EDM Power parameters input TR Pulse Mode: Voltage (30~150V), Current (1, 2, 4, 8, 16A), Pulse ON(3 ~ 999 µs), Pulse OFF (3 ~ 999 µs), Polarity, Single pulse mode R-C mode: Voltage (30~150V), Capacitor (user mountable 4 capacitors), Polarity, Single pulse mode EDM monitoring output (for Oscilloscope): Voltage, Current, Synchronizing Trigger pulse (in TR mode)

MACHINE VARIATIONS 

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Basic Machine is as CNC Milling machine (Spindle insulated) High Precision Version: Resolution : 0.1 micron (+/- 3 micron repeatability) EDM version : Basic Machine + EDM Power + Oil Tank(Pump) + Accessories EDM Drill Version : EDM Version + Flushing Spindle + High Pressure Pump + Electrode Feeding/Guiding Axis MPG optional

Basic Version

EDM Version

EDUCATIONAL VERSION Machine Specification  Machine Type: Table top type miniature milling machine  Machine Size: W400, D550, H600  Machine Travel: X150 x Y75 x Z80  Mechanical Resolution: 1 micron (+/- 10 micron repeatability)  Linear axes motor: Step motor with micro step driver  Spindle Motor: BLDC Motor, 200W, 3000RPM  Spindle Type: ER11 collect system (Φ4 & Φ 6 mm collects included)  Basic CNC control system installed in the machine column

MICRO-TURNING VIDEO

THANK YOU !

Sinergy Nano Systems [email protected]