Micro Manufacturing

ME 686: Micro-manufacturing Assignment 1 Consider the property of course parameters (speed, heal, profundity of cut etc. ) associated following a while SPDT for manufacturing of micro lens let vests. Also experience out the rambles of these course parameters and values of optimal course parameters. Submitted by: Marmeek Kishor Kumar Kosambia (09010332) Submitted to : Dr. S. N. Joshi Date of Submission: 17/01/13 Introduction A microlens vest is collected of a course of micro lens distributed in a systematic archetype and has been usedin a broad ramble of photonic products. A micro lens is a weak lens, generally following a while a diameter close than a millimetre (mm) and commonly as weak as 10 micrometers (µm). The weak extents of the lenses instrument that a artclose guile can furnish cheerful optical condition but casually unwanted property somethingt due to optical diffraction at the weak features. A natural micro lens may be a one component following a while one roll exterior and one round protuberant exterior to refract the characterless. Consequently micro lenses are so weak, the substreprimand that supports them is usually thicker than the lens and this has to be fascinated into totality in the guile. More abrupt lenses may use aspherical surfaces and others may use distinct layers of optical embodied to close their guile performance. Since exterior unmannerliness concerns the performance of the lens, one needs to beget finely machined exterior following a while poverty unmannerliness One Point Diamond Turning machining is a technique which removes embodieds from a few microns to sub-micron horizontalten to close docile mode machining on hard-to-machine embodieds such as electro close nickel plating, silicon, quartz, glass and ceramics following a while no subexterior defects. Such a machining course is conducive to close meditate exterior conclude of close than 10 nm and make untruth of close than 1um largely. If appropriately applied to a specific ramble of diamond turnconducive embodieds, the course is far eminent to heavy and polishing where model govern is past hard and courseing interval is longer. The selecting and optimization of machining parameters is one of the deep factors that could govern the machining endment. The deep machining parameters are hireling heal reprimands, spindle urge and profundity of cut. The hireling heal reprimand is normally familiar in provisions of either interspace travelled by the hireling per item interval (mm/min) or interspace travelled per item order (mm/revolution). It is most sordid to see the interspace per form as it is straightway kindred to the anticipated speculative exterior conclude. For a furnishn hireling heal reprimand, larger the hireling nose radius, inferior the unmannerliness and the emend the optical exterior conclude. The exterior condition depends to magnanimous extents on the embodied characteristics like: atom extent, micro construction or crystal designation, crystal tenor and annealing procedures adopted. Casual choice of association of machining parameters may concern the exterior condition, so it is required to optimize the machining parameters antecedently terminal SPDT course. Machining of aspheric exterior is past perplexed than round and horizontal exteriors consequently of perplexed hireling route and abstruse embodied resistance. To close required form hireling route should be optimized. Exterior unmannerliness following a while regard to variconducive Heal reprimand Heal reprimand is most extensive parameter and diversity of this accepta magnanimous application on the exterior conclude. Speculative exterior concludedepends on heal reprimand and hireling radius. Depth of cut 2 ? m andRPM 1000 kept perpetual and hireling heal reprimand is divers from 0. 5? m/rev to 5. 0 ? m/rev. the fruits of the trials are asfollows. From the over trials, it is observed that the exterior conclude is going down as we bring heal. The exterior unmannerliness is 54. 8 nm at heal 0. 5 ? m where the profundity of cut is 2 ? m and 1000 RPM was deeptained. It is investigated that although behold of the exterior was cheerful but it is not of optical condition at these parameters. We accept divers the profundity of cut at heal reprimand of 0. 5. Exterior unmannerliness following a while regard to variconducive profundity of cut From the over trials, it is observed that the exterior conclude is depending on the profundity of cut but its demeanor is opposed. As we acception the doc from 1? m to 2 ? m the unmannerliness reduce from 117 nm to 54 nm and commonly acception the unmannerliness on of doc. Same is commonly common on 8 ? m doc. The exterior unmannerliness is 54. 8 nm at heal 0. 5 ? m/rev where the profundity of cut is 2 ? m and 1000 RPM. But it is investigated that exterior is not optical at these parameters, the exterior condition was sad following 10 ? m doc and there no use of increasing the doc past than 10 ? m. From the over trials, it is observed that the exterior conclude is depending on the profundity of cut but its demeanor is opposed. As we acception the doc from 1? m to 2 ? m the unmannerliness reduce from 117 nm to 54 nm and commonly acception the unmannerliness on of doc. Same is commonly common on 8 ? m doc. The exterior unmannerliness is 54. 8 nm at heal 0. 5 ? m/rev where the profundity of cut is 2 ? m and 1000 RPM. But it is investigated that exterior is not optical at these parameters, the exterior condition was sad following 10 ? m doc and there no use of increasing the doc past than 10 ? m. Surface unmannerliness following a while regard to variconducive RPM From the decisive trial we accept seen that the profundity of cut 2 ? m giving the emend exterior. During this trial heal reprimand 0. 5 ? m/rev and profundity of cut remained unchanged and RPM divers from 800 to 4000, to get the excite emend exterior on the performance concern. Analysis of churlish performance concern at opposed RPM is carried out. Output fruit is shown in over consultation. By trials we accept seen that polycarbonate exterior churlish to the exterior conclude of beneath 25 nm, which is closed at RPM 3000. A cheerful exterior conclude is closed at 800 RPM also but it is not restricted. At RPM 1500 we accept observed the something archetype on exterior of PC. So, RPM 3000, Heal 0. 5 ? m/rev and profundity of cut 2 ? m are the optimum parameters where optical exterior is closed. An tentative makeula is familiar for predicting exterior unmannerliness of diamond churlish polycarbonate at opposed turning parameters (heal reprimand, profundity of cut and RPM). Tentative makeula is superficial as follows. Optimum turning parameter are suggested where the optical exterior conclude in obtained. Hireling heal reprimand : 0. 5 ? m/form Profundity of cut : 2 ? m RPM : 3000 Hireling Route Compensation Another consider shows the magnanimousest brave lies in selecting the optimum association of the course parameters to get the best exterior condition. The parameters clarified for optimization are as: Spindle urge (SS), Heal reprimand (TFR), Profundity of cut (DoC). Another parameter to optimize the machining is the hireling route. The hireling route restoration cycle somethingts following a while the determination of desired aspheric exterior by the conic equation: It is observed that by modifying the hireling route, form untruth ofaspheric exterior is significantly bringd. The similarity among aspheric appearance untruth, antecedently and following hireling route restoration is furnishn in Table-4. Conclusions: 1) Hireling heal is the dominant parameter for exterior unmannerliness followed by the spindle orderal urge. Profundity of cut shows minimal result on exterior unmannerliness compared to other parameters. 2) Profundity of cut is the necessary parameter for peak to dip untruth, followed by spindle orderal urge. Heal reprimand does not accept considerconducive result on Pt. 3) Result of profundity of cut on Pt varies following a while spindle urge. However, for achieving cheerful optical exterior on the polycarbonate performance concern, inferior profundity of cut is preferred. 4) Spindle orderal urge of 2000rpm, hireling heal reprimand of1? m/rev and profundity of cut of 2? are separated for precisemachining of polycarbonate. 5) The course of the optimization of hireling route helps to optimize the machining course excite. References: 1. V. SainiD. SharmaS. KallaT. Chouhan, ‘Optimization of Course Parameters to Close Nano LevelSurface Condition on Polycarbonate’, Proceedings of the International Conference on Manufacturing Excellence, 2012 2. N. KhatriV. MishraR. G. V. Sarepaka, ‘Optimisation of course parameter in ultra-precisiondiamond turning of polycarbonate embodied’, International Journal of Computer Applications (0975 – 888) Volume 48– No. 13, June 2012