Engineering Materials Kapil Gupta Editor Micro and Precision Manufacturing Engineering Materials The “Engineering Materials” series provides topical information on innovative, structural and functional materials and composites with applications in optical, electronical, mechanical, civil, aeronautical, medical, bio and nano engineering. The individual volumes are complete, comprehensive monographs covering the structure, properties, manufacturing process and applications of these materials. This multidisciplinary series is devoted to professionals, students and all those interested in the latest developments in the Materials Science field. More information about this series at http://www.springer.com/series/4288 Kapil Gupta Editor Micro and Precision Manufacturing 123 Editor KapilGupta Department ofMechanical andIndustrial EngineeringTechnology University of Johannesburg Johannesburg SouthAfrica ISSN 1612-1317 ISSN 1868-1212 (electronic) Engineering Materials ISBN978-3-319-68800-8 ISBN978-3-319-68801-5 (eBook) https://doi.org/10.1007/978-3-319-68801-5 LibraryofCongressControlNumber:2017954465 ©SpringerInternationalPublishingAG2018 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. 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Printedonacid-freepaper ThisSpringerimprintispublishedbySpringerNature TheregisteredcompanyisSpringerInternationalPublishingAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland Preface Micro-manufacturing and precision manufacturing entail the use of sophisticated techniquesinorder toattain special manufacturingrequirements, suchas precision machining and finishing of various DTM, bio and smart materials; micro-manufacturingofmechanicalcomponents;machiningofintricateshapesand features; and precision finishing of engineered products. To accomplish the aforementioned tasks, a number of conventional and advanced processes are strategically exploited. Therefore, knowledge of working principle, process mechanism, and control and accuracy of these processes is essential for their successful implementation. Thisbookconsistsofatotalofeightchaptersemphasizingnovelaspects,current trends and latest developments in micro- and precision manufacturing. Chapter “Machining of Microshapes and Features” details manufacturing of micro-shapes and features by various conventional and advanced processes. Chapter “Electrochemical Methods of Micropart’s Manufacturing” describes mechanism and working ofelectrochemicalmachining for micro-parts manufacturing.Chapter “Precision Photochemical Machining” is dedicated to precision photochemical machining.Chapter“Nano-Machining,Nano-JoiningandNano-Welding”highlights thedevelopmentofnano-manufacturingwithfocusonnano-machining,joiningand welding. Ultraprecision finishing techniques for fabrication of optical components are discussed in Chapter “Fabrication of Optical Components by Ultraprecision FinishingProcesses”.Chapter“ConditionMonitoringinMicro-InjectionMoulding” discussestheimportantaspectsofconditionmonitoringinmicro-injectionmoulding. Chapter“SurfaceFinishImprovementofAdditiveManufacturedMetalParts”sheds lightonsomepost-finishingmethodsforadditivemanufacturedmetalparts.Chapter “PrecisionCoatings”isanimpressivenoteonprecisioncoatingsandhighlightstheir principleandapplicationsforvariousengineeredparts. v vi Preface This book is intended to facilitate the industrial, research and academic com- munitybyensuringknowledgeenrichmentintheoreticalandresearchaspectsofthe techniquesused tofulfilvarious micro- andprecision manufacturingrequirements. I thank all the authors for their valuable contribution. Johannesburg, South Africa Kapil Gupta June 2017 Contents Machining of Microshapes and Features . . . . . . . . . . . . . . . . . . . . . . . . 1 Asma Perveen and Carlo Molardi Electrochemical Methods of Micropart’s Manufacturing . . . . . . . . . . . . 21 Sebastian Skoczypiec Precision Photochemical Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Atul R. Saraf, Shivam P. Yadav and M. Sadaiah Nano-Machining, Nano-Joining, and Nano-Welding. . . . . . . . . . . . . . . . 71 Kush Mehta, Munish Gupta and Priyanranjan Sharma Fabrication of Optical Components by Ultraprecision Finishing Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Gourhari Ghosh, Ajay Sidpara and P.P. Bandyopadhyay Condition Monitoring in Micro-Injection Moulding. . . . . . . . . . . . . . . . 121 C.A. Griffiths Surface Finish Improvement of Additive Manufactured Metal Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Hany Hassanin, Amr Elshaer, Redha Benhadj-Djilali, Francesco Modica and Irene Fassi Precision Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Zoltan-Iosif Korka Index .... .... .... .... .... ..... .... .... .... .... .... ..... .... 195 vii About the Editor Dr. Kapil Gupta is a Senior Lecturer in the Department of Mechanical and IndustrialEngineeringTechnologyattheUniversityofJohannesburg,SouthAfrica. His research interests include advanced machining processes, sustainable manu- facturing, microfabrication, precision engineering and gear technology. ix Machining of Microshapes and Features Asma Perveen and Carlo Molardi Abstract Accelerated trend of miniaturization and thereby increasing use of microfeatures and microparts have tremendously encouraged scientists and engi- neers to develop new techniques for their precision fabrication. Considering that, this chapter introduces various machining techniques for microfeature fabrication, their capabilities, salient features and associated surface integrity aspects. It also reviewsthepastworkandhighlightsrecenttechnologicaldevelopmentinthisarea. (cid:1) (cid:1) (cid:1) Keywords Microholes Laser machining Electro discharge machining Electrochemical discharge machining 1 Introduction Increasing demand for developing micromachining technology to fabricate micro- features andmicroshapeshasbeenattractingtheinterest ofresearchers tofulfilthe specific requirements of aerospace, biomedical, electronics and automotive indus- tries[1,2].Downscalingtrendofprocesses,machines,metrologyinordertosatisfy the current needs of smaller, thinner and lighter products with accuracy and pre- cision appears to push the established technologies towards miniaturization. Manufacturing of engineered parts and components with feature size ranging from 1 to 999 µm is known as micromanufacturing [1, 2]. In order to satisfy current needs, innovative micromachining processes other than the improvement in the existingmachiningtechnologieshavebecomecrucial.Nevertheless,thisjourneyof A.Perveen(&) DepartmentofMechanicalEngineering,NazarbayevUniversity, 53KabanbayBatyrAve.,Astana010000,RepublicofKazakhstan e-mail:[email protected] C.Molardi DepartmentofElectricalandElectronicsEngineering, NazarbayevUniversity,53KabanbayBatyrAve.,Astana010000 RepublicofKazakhstan ©SpringerInternationalPublishingAG2018 1 K.Gupta(ed.),MicroandPrecisionManufacturing,EngineeringMaterials, https://doi.org/10.1007/978-3-319-68801-5_1