Accepted Manuscripts

Tatsuhiko Aizawa, Hiroshi Tamagaki and Kenji Wasa
J. Micro Nano-Manuf   doi: 10.1115/1.4039358
The plasma oxidation printing was proposed as a digital manufacturing to shape the diamond-like carbon (DLC) thick film into a micro-nozzle on the tool steel substrate. Its head shape was first designed by CAD (Computer Aided Design) and printed onto DLC film by the maskless lithography. The unprinted DLC was removed in depth by the anisotropic etching. Fine circular nozzle with the inner diameter of 10 ?m and the height of 10 ?m was fabricated during the duration time of 3.6 ks. Different from the micro-milling or the micro electric discharging, the micro-nozzle geometry is directly fabricated from its CAD data. The micro-nozzle with the cross-star outlet was constructed without change of processing procedure and without use of tooling.
TOPICS: Manufacturing, Nozzles, Plasmas (Ionized gases), oxidation, Printing, Computer-aided design, Micronozzles, Shapes, Micromilling, Maskless lithography, Tooling, Anisotropy, Carbon, Diamonds, Etching, Geometry, Diamond films, Tool steel, Thick films
Sachin Singh, T. N Deepu Kumar, Mamilla Ravi Sankar and K.P. Rajurkar
J. Micro Nano-Manuf   doi: 10.1115/1.4039295
Miniaturization of components is one of the major demands of the today's technological advancement. Microslotsare one of the widely used microfeature found in various industries such as automobile, aerospace, fuel cells and medical. Surface roughness of the microslots plays critical rolein high precision applications such as medical field (e.g.drug eluting stent and microfilters). In the present paper, abrasive flow finishing (AFF) process is used for finishing of the microslots (width 450 µm) on surgical stainless steel workpiece that are fabricated by electrical discharge micromachining. AFF medium is developed in-house and used for performing microslots finishing experiments. Developed medium not only helps in the removal of hard recast layer from the workpiece surfaces but also provides nano surface roughness. Parametric study of microslots finishing by AFF process is carried out with the help ofcentral composite rotatable design method. The initial surface roughness on the microslots wall is in the range of 3.50 ± 0.10 µm. After AFF, the surface roughness is reduced to 192 nm with a 94.56 % improvement in the surface roughness. To understand physics of the AFF process,3-D finite element viscoelastic model of the AFF process is developed. Later, a surface roughness simulation model is also proposed to predict the final surface roughness after the AFF process. Simulated results are in good agreement with the experimental results.
TOPICS: Finishing, Modeling, Surgery, Flow (Dynamics), Stainless steel, Surface roughness, Biomedicine, Physics, stents, Composite materials, Aerospace industry, Design methodology, Finite element analysis, Fuel cells, Automobiles, Drugs, Micromachining, Simulation models

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