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Special Section Papers

Micro-Abrasive Water Jet and Micro-WEDM Process Chain Assessment for Fabricating Microcomponents

[+] Author and Article Information
Francesco Modica

STIIMA-CNR,
Institute of Intelligent Industrial Technologies and
Systems for Advanced Manufacturing,
National Research Council of Italy,
Via Paolo Lembo 38F,
Bari 70124, Italy
e-mail: francesco.modica@stiima.cnr.it

Vito Basile

STIIMA-CNR,
Institute of Intelligent Industrial Technologies and
Systems for Advanced Manufacturing,
National Research Council of Italy,
Via Paolo Lembo 38F,
Bari 70124, Italy
e-mail: vito.basile@stiima.cnr.it

Francesco Viganò

Department of Mechanical Engineering,
Politecnico di Milano,
Via Giuseppe La Masa, 1,
Milano 20156, Italy
e-mail: francesco.vigano@polimi.it

Francesco Arleo

WatAJet S.r.l.,
Via Tomasetto, 31,
Besnate, VA 21010, Italy
e-mail: francesco.arleo@watajet.com

Massimiliano Annoni

Department of Mechanical Engineering,
Politecnico di Milano,
Via Giuseppe La Masa, 1,
Milano 20156, Italy
e-mail: massimiliano.annoni@polimi.it

Irene Fassi

Mem. ASME
STIIMA-CNR,
Institute of Intelligent Industrial Technologies and
Systems for Advanced Manufacturing,
National Research Council of Italy,
Via Alfonso Corti 12,
Milano 20133, Italy
e-mail: irene.fassi@stiima.cnr.it

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO-AND NANO-MANUFACTURING. Manuscript received November 12, 2018; final manuscript received February 20, 2019; published online April 11, 2019. Assoc. Editor: Martin Jun.

J. Micro Nano-Manuf 7(1), 010903 (Apr 11, 2019) (6 pages) Paper No: JMNM-18-1048; doi: 10.1115/1.4042966 History: Received November 12, 2018; Revised February 20, 2019

The capability to manufacture high-precision components with microscale features is enhanced by the combination of different micromanufacturing processes in a single process chain. This study explores an effective process chain that combines micro-abrasive water jet (μ-AWJ) and microwire electrical discharge machining (μ-WEDM) technologies. An experimental spring component is chosen as a leading test case, since fine geometric features machining and low roughness on the cut walls are required. The advantages deriving from the two technologies combination are discussed in terms of machining time, surface roughness, and feature accuracy. First, the performances of both processes are assessed by experimentation and discussed. Successively, different process chains are conceived for fabricating two test cases with different sizes, displaying some useful indications that can be drawn from this experience.

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References

Hansen, H. N. , Carneiro, K. , Haitjema, H. , and De Chiffre, L. , 2006, “ Dimensional Micro and Nano Metrology,” CIRP Ann., 55(2), pp. 721–743. [CrossRef]
Uhlmann, E. , Mullany, B. , Biermann, D. , Rajurkar, K. P. , Hausotte, T. , and Brinksmeier, E. , 2016, “ Process Chains for High-Precision Components With Micro-Scale Features,” CIRP Ann. Manuf. Tech., 65(2), pp. 549–572. [CrossRef]
Lauwers, B. , Klocke, F. , Klink, A. , Tekkaya, E. , Neugebauer, R. , and Mcintosh, D. , 2014, “ Hybrid Processes in Manufacturing,” CIRP Ann., 63(2), pp. 561–583. [CrossRef]
Skoczypiec, S. , 2017, “ The Role of Unconventional Manufacturing Processes in Modern Manufacturing Chain,” Innovations in Management and Production Engineering, R. Knosala , ed., Publishing House of the Polish Society for Production Management, Opole, Poland, pp. 815–826.
Puri, A. B. , 2017, “ Advancements in Micro Wire-Cut Electrical Discharge Machining,” Non-Traditional Micromachining Processes, Chap. 4, Springer, Cham, Switzerland.
Matsumura, T. , Muramatsu, T. , and Fueki, S. , 2011, “ Abrasive Water Jet Machining of Glass With Stagnation Effect,” CIRP Ann. Manuf. Tech., 60(1), pp. 355–358. [CrossRef]
Jafar, R. H. M. , Nouraei, H. , Emamifar, M. , Papini, M. , and Spelt, J. K. , 2015, “ Erosion Modeling in Abrasive Slurry Jet Micro-Machining of Brittle Materials,” J. Manuf. Processes, 17, pp. 127–140. [CrossRef]
Annoni, M. , Arleo, F. , and Viganò, F. , 2017, “ Micro-Waterjet Technology,” Micro-Manufacturing Technologies and Their Applications, I. Fassi and D. Shipley , eds., Springer, Cham, Switzerland, Chap. 5.
Modica, F. , Marrocco, V. , and Fassi, I. , 2017, “ Micro-Electro-Discharge Machining (Micro-EDM),” Micro-Manufacturing Technologies and Their Applications, I. Fassi and D. Shipley , eds., Springer, Cham, Switzerland, Chap. 6.
Momber, A. W. , and Kovacevic, R. , 1998, Principles of Abrasive Water Jet Machining, Springer, London.

Figures

Grahic Jump Location
Fig. 2

Micro-abrasive water jet performance for plate thickness of 2 mm: (a) wall taper angle versus feed rate and (b) Ra versus feed rate

Grahic Jump Location
Fig. 3

Microwire electrical discharge machining finishing technologies: average process speed versus surface roughness for two levels of stock allowance

Grahic Jump Location
Fig. 4

Drawing of the spring

Grahic Jump Location
Fig. 5

Toolpaths: (a) rough trimming by μ-AWJ, (b) finishing by μ-WEDM, and (c) μ-AWJ machined sample

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