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17th Feb’2009

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Modern Trends in Machining & Materials, VJTI -


Mumbai

MICRO ENGINEERING

Aseem Suri
Sinergy Nano Systems
Mumbai- India
SINERGY NANO SYSTEMS

 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. Microsystems, MEMS, micro
sensors and a host of other disciplines like micro-fluidics and
micro robotics are being developed. “Micro Systems” thesis
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 the 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 - EDM
Micro - ECM
Micro-wire EDM
Micro-turning
Micro-Milling
Micro - three of a kind
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 CAPABILITIES-
1

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 micro
milling.
MICRO MACHINING CAPABILITIES-
2

Micro EDM
30-micron shafts and 50-
micron 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 - SILICONE
MACHINE BUILDING

 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 at
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 for 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
 Table top miniature EDM machine.
 Granite base size: 300mm x 300mm x
80mm
 Total height: 500mm (approximately)
 Resolution: 1 µm
 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

 Basic Machine is as CNC Milling


machine (spindle insulated)
 High Precision Version: Resolution
: 0.1 micron (+/- 3 micron
repeatability)
 EDM version: Basic Machine +
Basic version
EDM Power + Oil Tank (Pump) +
Accessories
 EDM Drill Version: EDM Version EDM Version
+ Flushing spindle + high
Pressure pump + electrode
Feeding / guiding axis
 MPG optional
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]