Materials Forming, Machining and Tribology

Series editor J. Paulo Davim, Aveiro, Portugal More information about this series at http://www.springer.com/series/11181 Golam Kibria • B. Bhattacharyya J. Paulo Davim Editors

Non-traditional Micromachining Processes Fundamentals and Applications

123 Editors Golam Kibria J. Paulo Davim Department of Mechanical Department of Mechanical Engineering Aliah University of Aveiro Aveiro Portugal

B. Bhattacharyya Department of Production Engineering Kolkata India

ISSN 2195-0911 ISSN 2195-092X (electronic) Materials Forming, Machining and Tribology ISBN 978-3-319-52008-7 ISBN 978-3-319-52009-4 (eBook) DOI 10.1007/978-3-319-52009-4

Library of Congress Control Number: 2016963424

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This Springer imprint is published by Springer Nature The registered company is Springer International Publishing AG The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland Preface

Since the last decade, the major research challenges and developments around the globe are to manufacture microcomponents with high accurate of microfeatures which have geometrical dimensions even less than tens of microns. It is obvious that the demand of microcomponents is diversely increasing day by day in the field of aviation, automotive, biomedical, optical, electronics, and energy sectors. This wide range of applications of microcomponents brings the necessity to develop promising micromachining which can yield high degree of precision, improved machining rate with accurate geometrical dimensions, reliability, flexi- bility, and after all environment friendly. Moreover, the developments of material provide materials which have enormous material properties especially in their machinability and hardness. In this situation, it is the task of manufacturer engineers to develop micromachining processes, both traditional and non- traditional, which can fulfill the demands of microproduct having several micro- and nanofeatures. In the area of non-traditional micromachining processes, few books are avail- able. These books mostly describe numerical and experimental research details at different stages. However, it is the most important task at this stage to gain the fundamental knowledge about different non-traditional micromachining processes. Not only that, but it is also important to be acquainted with the capabilities and applications of these micromachining processes in various product manufacturing. Moreover, several hybrid micromachining processes have also been developed to improve the surface integrity, geometrical accuracy, and machining efficiency. The present book entitled “Non-traditional Micromachining Processes—Fundamentals and Applications” will definitely fulfill the gap between the demand of microfea- tured components and successful micromachining of these products. This book starts with introduction of various micromachining processes, espe- cially, non-traditional, with recent research and developments in each processes. Further, mechanical type micromachining process such as micro-USM is presented with mechanism of material removal, types and technologies of micro-USM and recent research advancements. Then, electro-thermal processes such as micro-EDM, wire-EDM, micromachining using laser beam (micro-turning,

v vi Preface micro-cutting, etc) were discussed. Further, electrochemical micromachining pro- cess was discussed for micromachining and micro fabrication of various complex and high accuracy profiles. Then, hybrid type micromachining such as micro electrochemical discharge machining processes were presented. Chapter 1 gives an overview of various micromachining processes including various hybrid and nanofinishing processes with their applications, working principles, challenges in scaling down a macro machining process to a micromachining process, and some recent developments in each category of process. Chapter 2 describes the overview of microultrasonic machining process with brief description of process parameters, system details, and recent development and research challenges for micromachining of intricate parts with high degree of accuracy and surface profile. Chapter 3 describes the overview of EDM and micro-EDM process with details of significant process parameters and experimental investigation with analysis of microhole machining process utilizing some novel machining strategies such as microtool rotation, polarity changing, utilization of deionized water as dielectric, implemen- tation of boron carbide additives into dielectrics. In Chap. 4, a brief introduction of microwire electrical discharge machining (MWEDM) is presented with details of micromachining system, wire failure prevention, detailed analysis of charging and discharging circuits, and details of wire lag and vibration phenomena during micromachining of complex geometrical components. Chapter 5 deals with the experimental investigation and analysis on pulsed Nd:YAG laser microturning process of aluminum oxide ceramics. This process is new in the category of laser micromachining process, and a lot of research and developments are still needed for exploring the capabilities of pulsed Nd:YAG laser for obtaining high precision microparts with required surface finish. In Chap. 6, the overall concept of fiber laser micromachining and influence of machining process parameters on geometrical accuracy of microparts is presented. The chapter also describes various microma- chining processes such as microcutting, microdrilling, engraving, and marking using fiber laser systems on wide range of materials from polymer to ceramics. In Chap. 7, in-depth experimental study and analysis are carried out during laser beam cutting of Inconel 625 superalloy at dry condition to explore the influence of various process parameters on kerf width utilizing pulsed Nd:YAG laser micro- machining system. In Chap. 8, fundamental of anodic dissolution of microelec- trochemical machining is presented with brief overview of significant process parameters and important techniques for improving the machining accuracy and reliability by implementing novel geometry of microtool and its insulation during microchannel formation using EMM process. Chapter 9 presents a detailed over- view of electrochemical micromachining of titanium and its alloy and the effect of process parameters on feature profile during maskless and through mask EMM. Chapter 10 provides the fundamental aspect of microelectrochemical discharge machining process and description of machining system and process parameters. The chapter also describes the research and development carried out around the globe in microdrilling and microcutting using micro-ECDM. Chapter 11 presents the overview of travel wire electrochemical spark machining (TWECSM), the development of micromachining setup, brief discussion of process parameters, and Preface vii parametric effect on machining rate and spark gap width during machining of glass fiber epoxy composite. This book offers a comprehensive treatment of various non-traditional micro- machining techniques and future directions representing a valuable reference to engineers and R&D researchers involved in micromachining. The present book can also be used as a research book for final undergraduate engineering course or as a topic on micromachining processes at the postgraduate level. Also, this book can serve as a useful reference for academics, researchers, mechanical, manufacturers, industrial and materials engineers, professionals in micromachining processes and related industries. The scientific interest in this book is evident from many important centers of the research, laboratories, as well as industries. Therefore, it is hoped that this book will inspire and enthuse others to undertake research in non-traditional micromachining processes. The editors acknowledge Springer for this opportunity and for their enthusiastic and professional support. Finally, we would like to thank all the chapter authors for their availability for this work.

Kolkata, India Golam Kibria Kolkata, India B. Bhattacharyya Aveiro, Portugal J. Paulo Davim Acknowledgements

This book has become a reality due to the constant inspirations and encouragement received from the senior professors and colleagues like Dr. B. Doloi, Dr. D. Banerjee, and Dr. B.R. Sarkar of Production Engineering Department, Jadavpur University, Kolkata; Dr. B.B. Pradhan and Mr. I. Shivakoti of Sikkim Manipal Institute of , Sikkim, India. The editors would like to convey warm regards to Dr. A. Manna, Dr. S. Dhobe, Dr. V.U. Rathod, Dr. Sandip S. Anasane, Dr. Josephine Peter, Dr. Mukandar Sekh, Dr. Shamim Haider, and Mr. Omar Faruk Biswas for constant support and active participation in preparing the manuscripts of this book. Financial support from the University Grants Commission (UGC), All India Council for Technical (AICTE), Department of Science and Technology (DST), and Council of Scientific and Industrial Research (CSIR) for carrying out research in this area has proved to be useful for utilizing research outcomes to enrich this book. The editors acknowledge Springer for this opportunity and for their enthusiastic and professional support. The team members of Springer like Guido Zosimo Landolfo, Editorial Director; Dr. Dieter Merkle, Springer International Publishing (Physical and Engineering); and Dr. Mayra Castro, Applied Sciences Editorial and Senior Publishing Editor of Springer have put their constant effort in transforming this book into its final shape. Finally, I would like to thank all the chapter authors for their availability for this work.

Kolkata, India Golam Kibria Kolkata, India B. Bhattacharyya Aveiro, Portugal J. Paulo Davim January 2017

ix Contents

1 Non-traditional Micromachining Processes: Opportunities and Challenges ...... 1 S. Debnath, S. Kunar, S.S. Anasane and B. Bhattacharyya 2 Recent Advancement on Ultrasonic Micro Machining (USMM) Process ...... 61 S. Das, B. Doloi and B. Bhattacharyya 3 Electrical Discharge Micro-hole Machining Process of Ti–6Al–4V: Improvement of Accuracy and Performance ...... 93 Golam Kibria, I. Shivakoti, B.B. Pradhan and B. Bhattacharyya 4 Advancements in Micro Wire-cut Electrical Discharge Machining ...... 145 Asit Baran Puri 5 Laser Micro-turning Process of Aluminium Oxide Ceramic Using Pulsed Nd:YAG Laser ...... 179 Golam Kibria, B. Doloi and B. Bhattacharyya 6 Fiber Laser Micro-machining of Engineering Materials...... 227 A. Sen, B. Doloi and B. Bhattacharyya 7 Laser Beam Micro-cutting ...... 253 N. Roy, A.S. Kuar and S. Mitra 8 Electrochemical Micromachining (EMM): Fundamentals and Applications ...... 275 V. Rathod, B. Doloi and B. Bhattacharyya 9 Electrochemical Micromachining of Titanium and Its Alloys...... 337 Sandip S. Anasane and B. Bhattacharyya

xi xii Contents

10 Electrochemical Discharge Micro-machining of Engineering Materials ...... 367 B.R. Sarkar, B. Doloi and B. Bhattacharyya 11 Travelling Wire Electrochemical Spark Machining: An Overview ...... 393 Anup Malik and Alakesh Manna Index ...... 413 Editors and Contributors

About the Editors Dr. Golam Kibria is an assistant professor in the Department of Mechanical Engineering in Aliah University, Kolkata, India. He completed his M.Tech. in Production Engineering from Jadavpur University, Kolkata in 2008 and Ph.D. from Jadavpur University, Kolkata, in 2014. He has worked as a senior research fellow (SRF) in Council of Scientific and Industrial Research (CSIR)-spon- sored project from 2008 to 2011. His research interests include non-conventional machining processes, micromachining, and advanced manufacturing and forming technology. He is a life member of The Institution of Engineers (IEI), India. He is the author of several chapters on internationally recognized book publishers such as Elsevier, Springer, and Nova Publishers. He has also published 26 International and national research papers in various reputed journals and 37 research papers in reputed national and international conference proceedings. He is an editorial board member as well as a reviewer of a number of reputed international journals, namely Optics and Laser Technology, International Journal of Advanced Manufacturing Technology, Manufacturing Review, and International Journal of Physical Sciences. In his credit, he has received I.S.T.E. National Award for Best M.Tech. Thesis in Mechanical Engineering in 2008. He also received the Institution Prize (Gold Medal) of 2008–2009 from The Institution of Engineers (India) for the best paper.

B. Bhattacharyya is a professor and ex-head of the Production Engineering Department and coordinator of Center of Advance Study Programme under University Grants Commission and Quality Improvement Programme under AICTE of Jadavpur University. His research areas include non-traditional machining, micromachining, and advanced manufacturing systems. He has pub- lished 108 research papers in National and International Journals and 271 research papers in National and International Conferences. He has published several chapters and conference proceedings. Recently, he has published one book titled “Electrochemical Micromachining for Nanofabrication, MEMS and Nanotechnology,” William Andrew Applied Science Publishers, Micro and Nano Technologies Series, Elsevier Inc, USA. Several Ph.D. theses have been completed under his guidance. He has completed several research projects. He is recipient of various awards, e.g., Gold Medal and Certificate of Achievements for research papers and thesis as well as the Career Award of the UGC, New Delhi.

J. Paulo Davim received his Ph.D. in Mechanical Engineering in 1997, M.Sc. degree in Mechanical Engineering (materials and manufacturing processes) in 1991, Licentiate degree (5 years) in Mechanical Engineering in 1986, from the University of Porto (FEUP), the Aggregate title from the University of Coimbra in 2005, and a D.Sc. from London Metropolitan University in 2013. He is Eur Ing and Senior Chartered Engineer by the Portuguese Institution of Engineers with

xiii xiv Editors and Contributors a MBA and Specialist title in Engineering and Industrial . Currently, he is a professor at the Department of Mechanical Engineering of the University of Aveiro. He has more than 30 years of teaching and research experience in Manufacturing, Materials, and Mechanical Engineering with special emphasis in Machining and Tribology. Recently, he has also interest in Management/Industrial Engineering and for Sustainability/Engineering Education. He has received several scientific awards. He has worked as a evaluator of projects for international research agencies as well as an examiner of Ph.D. thesis for many universities. He is the editor in chief of several international journals, guest editor of journals, books editor, book series editor, and scientific advisory for many international journals and conferences. Presently, he is an editorial board member of 30 international journals and acts as a reviewer for more than 80 prestigious Web of Science journals. In addition, he has also published as editor (and co-editor) more than 80 books and as author (and co-author) more than 10 books, 60 chapters, and 350 articles in journals and conferences (more than 200 articles in journals indexed in Web of Science/h-index 35+ and SCOPUS/h-index 44+).

Contributors Sandip S. Anasane Department of Production Engineering and Industrial Management, College of Engineering Pune, Pune, India B. Bhattacharyya Production Engineering Department, Jadavpur University, Kolkata, India S. Das Production Engineering Department, Jadavpur University, Kolkata, India S. Debnath Production Engineering Department, Jadavpur University, Kolkata, India B. Doloi Production Engineering Department, Jadavpur University, Kolkata, India Golam Kibria Mechanical Engineering Department, Aliah University, Kolkata, India A.S. Kuar Production Engineering Department, Jadavpur University, Kolkata, India S. Kunar Production Engineering Department, Jadavpur University, Kolkata, India Anup Malik Department of Mechanical Engineering, PEC University of Technology, Chandigarh, India Alakesh Manna Department of Mechanical Engineering, PEC University of Technology, Chandigarh, India S. Mitra Production Engineering Department, Jadavpur University, Kolkata, India B.B. Pradhan Mechanical Engineering Department, Sikkim Manipal Institute of Technology, Sikkim, India Asit Baran Puri Mechanical Engineering Department, National Institute of Technology Durgapur, Durgapur, West , India Editors and Contributors xv

V. Rathod Department of Mechanical Engineering, Government Polytechnic Ratnagiri, Maharashtra, India N. Roy Production Engineering Department, Jadavpur University, Kolkata, India B.R. Sarkar Production Engineering Department, Jadavpur University, Kolkata, India A. Sen Production Engineering Department, Jadavpur University, Kolkata, India I. Shivakoti Mechanical Engineering Department, Sikkim Manipal Institute of Technology, Sikkim, India