Hybrid and Reconfigurable

Micromanufacturing Processes


Ramesh Singh
Machine Tools Laboratory
Department of Mechanical Engineering
Indian Institute of Technology Bombay
Machine Tools Laboratory
Outline
Overview of Machine Tools Lab
Reconfigurable laser manufacturing processes
at micro/meso scales
Laser-assisted mechanical micromachining
Laser surface hardening
Laser cladding
Laser brazing
Laser texturing
Reverse EDM
Creating nanofinished cavities in single crystal
sapphire
Manufacturing process simulation
Research Interests
Machine Tools Laboratory

Micromachining
Characterization
& modeling steels
/layered pyrolytic
carbon
Burr formation
High speed
micromilling
mchine
development
Reconfigurable
fiber laser
manufacturing
Laser-assisted
micromachining
Laser hardening
Laser cladding
Laser brazing of
ceramics and
metals
Laser surface
texturing
Engineered
Surfaces
Functional
Response
hydrophobicity/
hydrophilicity
Tribological
response
Finite Element
Simulations
Electromagnetic
forming
Ring rolling
Flow forming
Composite
damage
Machine Tools Lab Facilities
Capital Equipment and instrumentation
Mikrotools CNC Multi-purpose Micromachining Center
EMCO Precision CNC Lathe
Hardinge Vertical Machining Center
100 W Single Mode Fiber Laser
Excimer Laser Micromachining Facility
Wyko NT 9100 White Light Interferometer
Zeiss 3D Coordinate Measuring Machine
Kistler Mini and large size force Dynamometers
Acoustic Emission Sensing System
Nikon Tool Makers Microscope
Micro-hardness Testing Machine
Image Analyzers
National Instruments Data Acquisition System/High speed
Digitizer
Computational Facilities
Deform 3D and 2D with Machining simulation modules
ANSYS and ABAQUS
Pro-Engineer
MATLAB and Simulink
COMSOL
Digimat
Characterization Tools and Equipments
Machine Tools Laboratory
Measuring
microscope
White light interferometer Coordinate measuring
machine
Stereo and metallurgical microscope
Fiber laser
Issues in Tool-based
Micromanufacturing
Processing difficult-to-machine steels, superalloys and
ceramics
Hard facing and repair techniques at micro/meso scales
Slow process requires innovative solutions to increase
productivity
Surface finishing is extremely challenging; traditional rigid
tool based grinding processes may be difficult
Stiffness issues in the micro-machine tool
Precise servo control for positional accuracy

Improvements in Micromanufacturing
Hybridization of mechanical micromachining
Laser-assisted mechanical micromachining
Reconfigurable laser manufacturing
Fabrication of arrayed microstructures to
improve productivity
Reverse micro-EDM
Development of soft tool nanopolishing
methods
Hydrodynamic nanopolishing


Machine Tools Laboratory
Laser Assisted Mechanical
Micromachining (LAMM)
Limitations of mechanical micromachining
Range of materials
Tool flexural strength/machine-tool system stiffness
Slow process

Hybrid laser assisted mechanical micromachining
(LAMM)
Integrates thermal softening with mechanical micro-cutting
Thermal softening of workpiece results in low cutting forces
Overcomes limitations of machine-tool system stiffness,
flexural strength and low MRR
Machine Tools Laboratory
Micromachining Cell
LAMM Setup
Laser Characteristics:
Yb fiber laser
2-35 W
= 1060 nm (invisible)
Spot size = 70/110 m
Tool Post
Dynamometer
Tool
Laser Collimator
Lens
X-Y Stage
Workpiece
Y-Z Stage
X Y
Tool Post
Tool
Focused Laser Beam
X-Y Precision Stages
Cutting Direction
(Y-axis)
Workpiece Feed (X-axis)
Dynamometer
Singh et al., 2007
Machine Tools Laboratory
Micromachining Cell
Laser Assisted Machining
L aser
C ollimator
Assembly
C utting Tool
and
Workpiece
L aser
C ollimator
Assembly
C utting Tool
and
Workpiece
-Milling Turning
Machine Tools Laboratory
Micromachining Cell
Laser-Assisted Micromilling
Surface roughness
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
2.5 12.5 22.5 27.5 37.5 47.5 52.5 62.5 72.5 77.5 87.5 97.5 103 113 123 128 138 148
Distance of cut (mm)
S
u
r
f
a
c
e

r
o
u
g
h
n
e
s
s

(
m
i
c
r
o
n
s
)
Surface Roughness Without Laser
Surface Roughness With Laser
Comparison of surface roughness
with and without laser in laser
assisted on A2 tool steel (62 HRc)
Without laser
With laser
Machine Tools Laboratory
Micromachining Cell
Forces in LAMM

0
5
10
15
20
25
30
Cutting Force Thrust Force
F
o
r
c
e

(
N
)
0 W
10 W
35 W
56%
Drop
46%
Drop
Effect of laser power on forces. Cutting conditions: 300 m tool width,
10 mm/min cuting speed and 25 m nominal depth of cut
Experimental Setup
CAD drawing of LAMM-based
orthogonal cutting setup
Snap of the LAMM setup
Total
RS
The stresses which exist in a body after removal of all external forces.
RS one of the most imp. parameter in controlling the functional
performance
The origins induced by non-uniform plastic deformation
RS due to
Mechanical
loading
RS due to
Thermal
loading
RS due to Phase
Transformation
Generation of RS in machining:
Elastic-plastic deformation
Elasticity recovery
After relaxation, plastic strain results in
compressive RS
Residual Stresses in LAMM
Surface Residual Stresses
-350
-300
-250
-200
-150
-100
-50
0
30 mm/min 60 mm/min
Conventional
LAMM
15 m Uncut Chip Thickness
0
50
100
150
200
250
30 mm/min 60 mm/min
Conventional
LAMM
25 m Uncut Chip Thickness
The residual stress in thrust direction becomes more
compressive (~ 34%) in LAMM

A significant reduction in tensile residual stress (50%-60%) can
be obtained with laser assistance cutting direction.

The laser heating and the mechanical load, the surface layer
expansion exceeds the thermal expansion of the substrate
surface.

This differential expansion between the surface and the
substrate induces more compressive residual stresses in LAMM
compared to conventional cutting
Thrust Direction Cutting Direction
cutting
Thrust
34 %
14 %
47 %
73 %
Johnson-Cook model
It defines the flow stress as a function of strain, strain
rate, and temperature during machining
Friction model:
] (x)/K exp[ 1 / chip N o t = =
chip
s K m
006 . 0 = /
chip
K ,with
q
N Nmax c (x) [1-(x/L ) ] o o =
Finite Element Modeling of LAMM
(
(

|
|
.
|

\
|

(
(
(

|
|
|
.
|

\
|
+ + =
-
-
m
room m
room
n
T T
T T
C B A 1 ln 1 ) (
0
c
c
c o
.
p
p
T T T T T
k k k Q C c V
x x y y z z t x

| | c c c c c c c c
| | | | | |
+ + + = +
| | | |
c c c c c c c c
\ . \ . \ .
\ .
Laser beam is modeled as moving heat source
Cylindrical window whose diameter is equal to that of laser
beam
The heat in this heat exchange process is Q
) T - hA(T wp wd = = q P Q
Therefore, total heat in machining is given by
Heat due to plastic work + Heat due to friction + Laser heat
The governing heat conduction equation:
Modeling of Laser Moving Heat Source:
Finite Element Modeling of LAMM
Cutting conditions and results:
Heat window and boundary
conditions:

Test No.

Depth of
cut (mm)
Cutting Conditions Measured Simulated
Cutting
speed
(m/min)
Feed rate
(mm/rev)
Cutting force
(N)
Cutting
force (N)
%
Error
2 (LAM) 0.25 100 0.125 130 121.38 6.6
3 (LAM) 0.25 200 0.125 95 103.54 8.9
4 (LAM) 0.25 200 0.25 185 200.5 8.1
All six degrees of freedom ( u
x
, u
y
, u
z
, |
x,
|
y,
|
z
= 0) are constrained for the workpiece

Tool is constrained in X and Y-direction and
velocity is imparted along Z-axis.
Simulation video
Simulations and results:
Results
177.28 N
121.38 N
103.54 N
200.53 N
1
Cutting force variation
Test 1 (Conv) Test 2 (LAM)
Test 3 (LAM) Test 4 (LAM)
Reduction in
Fc =
32%
Prediction of residual stresses in DEFORM
The material model must be an elastic-plastic.

The simulation has to be executed for a total time step long enough to reach the steady-state
condition

After several time steps, the tool has to be released from the machined surface (unloading
phase)and the workpiece is allowed to cool to an atmospheric temperature

Unloading phase simulation may be done either by keeping the same step time as used during
cutting or by keeping one second step time for less number of steps.

The numerical in depth residual stress profiles have to be gathered on machined surface using
State Variable option in DEFORM 3D.
Reconfigurable fiber laser
manufacturing
Machine Tools Laboratory
Fiber Lasers
Maintenance free
High wall plug efficiency
Excellent beam quality (M
2

< 1.1)
Available in single mode &
multimode
Available with high power
up-to 50 KW
Compact in size & portable

Properties Fiber
Laser
Nd:YAG CO
2
Disc
Wall Plug
Efficiency
30% ~ 5% ~10% 15%
Output Powers to 50kW to 6kW to 20Kw to 4kW
BPP (4/5 kW) < 2.5 25 6 8
Life 100,000 10,000 N.A. 10,000
Cooling Air/water Water water water
Floor Space (4/5
kW)
< 1 sq. m 6 sq. m 3 sq. m 4 sq. m
Operating Cost/
hr
$21.31 $38.33 $24.27 $35.43
Maintenance Not
Required
Often Required Often
CO2 and Nd:YAG lasers have been used in materials processing
but fiber lasers have following advantages:
Laser Optics Setup
Indian Patent Application No
442/MUM/2011 Filed on 17
February 2011

Method and device for
generating laser beam of
variable intensity distribution
and variable spot size
(a) (b)
Micrographs at P = 100 W and scan rate =
600 mm/min (a) beam diameter = 400
m; (b) beam diameter = 200 m
Temperature plot
(a)d= 400,(b)d= 200;
(Power=100W, scan rate 600
mm/min)
2 2
0 2 2
0
2 2 2 2
2 ' (( ') ')
exp[ ] exp[ ] '
8 ( ') 4 ( ') 4 ( ')
' '
[ ( ) ( )]
2 ( ') 2 ( ')
t
P dt z x vt x
T T dx
K t t a t t a t t
y x y x
erf erf
a t t a t t
o
o
t o
o o


=

+
+

} }
Temperature plot & micrographs
in laser hardening
Temperature distribution for uniform moving heat source

(a) (b)
Hardness distribution plot (P=100W,
beam diameter 200mm, scan
rate800mm/min)
Hardness Calculation & Hardness
Plot
[24]
Microstructure of LSH specimen. (A- martensite
needles, B-transition zone, C-un-transformed
zone) (P=100W, beam diameter- 400mm, scan
rate 400mm/min)(500X)
Comparison of Gaussian and
Uniform Intensity Beam
Contour plots for Gaussian & Uniform intensity beam (P=100W, Beam diameter: 400mm, Scan rate: 600mm/min)
Schematic showing Gaussian &
Uniform intensity beam beam
hardened geometries
Overlap Study
27
Hardness Vs % overlap
(P= 70W, Scan rate 600 mm/min, beam diameter:
300mm)
0
100
200
300
400
500
600
700
800
10% Overlap 20% Overlap 30% Overlap
H
a
r
d
n
e
s
s
(
H
v
)

First pass Overlap Second pass
Objective
To find the effect of overlap on
hardness and to find optimum overlap
0
10
20
30
40
50
60
70
80
90
%

n
u
m
b
e
r

o
f

f
i
n
e

g
r
a
i
n
s

(
b
e
l
o
w

1
.
2

m
)

57%
39%
38%
First pass
Overlap
Second pass
28
Increase in martensite and finer grain formation in second
pass
(A) (B)
Inverse Pole Figure (IPF) showing martensite in(A)
specimen without overlap (B) Specimen with 20%
overlap
(A) (B)
Phase map showing martensite in(A) specimen
without overlap (B) Specimen with 20% overlap
EBSD Results in First & Second Pass
Wear Test
29
Different types of hardened patterns
Objectives:
To find effect of micro-scale hardened patterns on wear
resistance
To compare wear of different hardened geometries & to find
out optimum hardened geometry
Specimen size of diameter 10 mm and beam with size of 300 m
Pin on disk set-up
Pin on Disk Setup
Wear for different hardened geometries
0
1
2
3
4
5
6
7
8
Unhardened Square Circular Criss-cross Fully
hardened
F
r
i
c
t
i
o
n
a
l


f
o
r
c
e

(
N
)

Frictional force for different hardened
geometries
0
10
20
30
40
50
60
70
80
90
Circular Criss-cross Square Fully
hardened
Unhardened
W
e
a
r

(

m
)

91%
Wear resistance improve drastically because of hardening.
Whereas there is slight difference in wear observed in different
hardened geometries.
Frictional force is inversely proportional to percent area hardened .
**** Wear of fully hardened (overlapped) specimen is 58% less than other
hardened patterns(i.e. Square, circular, criss-cross).
Wear Test: Key Findings
PREPLACED LASER CLADDING
PHASE DIAGRAM
Material Selection
Substrate: IS 2062
Clad: Ti-Co mixture (85 wt.% Co)



Ti-Co phase diagram (Massalaki et al., 1990)
PROCESS
Elemental Analysis
34
0
10
20
30
40
50
60
70
80
90
0 0.2 0.4 0.6 0.8
Percentage of Cobalt
Percentage of Cobalt
Distance from centre of clad
Phase Analysis
35
Measured Responses
Clad
Geometry

Hardness

Residual
Stresses
Nikon Measuring
Microscope

Microhardness Tester (
Shimadzu-HMV)

X-Ray Diffraction Tests
37
EFFECT OF PARAMETERS ON HARDNESS
0
50
100
150
200
250
B I C
60 mm/min
180 mm/min
H
a
r
d
n
e
s
s
(
H
V
)
Location
More
Dilution
0
50
100
150
200
250
B I C
100W
60W
H
a
r
d
n
e
s
s
(
H
V
)
Location
83%
increase
0
50
100
150
200
250
B I C
28 m
7 m
H
a
r
d
n
e
s
s
(
H
V
)
Location
D?
Default
Parameters:
P= 100 W;
v= 100 mm/min;
d= 28 microns
38
Higher presence of
intermetallic compound at
higher temperatures

Gradual change due to
higher dilution (Fe- bcc)

Investigating this
technology for getting a
desired value of hardness
help create better
solutions aimed at
improving wear
resistance.

EFFECT OF PARAMETERS ON HARDNESS
(fcc)
(ordered
fcc)
Initially-
Compressive residual stresses in the normal
Tensile residual stresses in the shear direction

After Cladding
Increase in value of compressive stresses in normal direction
Compressive stresses in the shear direction.

39
EFFECT OF PARAMETERS ON RESIDUAL STRESSES
-700
-600
-500
-400
-300
-200
-100
0
100
60 mm/min 180 mm/min
Normal Stress
Shear Stress
-500
-450
-400
-350
-300
-250
-200
-150
-100
-50
0
60 W 100 W
Normal Stress
Shear Stress
Shear stress goes
down by 50% as
laser power
reduced by 40%
-700
-600
-500
-400
-300
-200
-100
0
7 microns 28 microns
Normal Stress
Shear Stress
R
e
s
i
d
u
a
l

S
t
r
e
s
s
e
s


(
M
p
a
)

Difference in the coefficients of thermal expansion of the substrate and clad material leads to
generation of compressive stresses.

As the laser beam moves forward, the molten metal consolidates with the resolidified metal
which has been left behind.

Solidification begins at bottom, hence bonding internally in normal direction

Use for Repair
75% decrease in
beam diameter
increases shear
stress by 53%
Default
Parameters:
P= 100 W;
v= 100 mm/min;
d= 28 microns
FEM in Abaqus


40
Power (W) Beam
Diameter/Crater
diameter (m)
Feed rate
(mm/min)
Results/Remarks
50 30/300 7 Week joint/Failure
60 30/300 7 success
70 30/300 7 Success
80 30/300 7 Success/Alarm
Table. Gaussian beam parametric study
Substrates: Alumina and SS 316, ABA: Cusil foil
Dia.30 m
Alumina
SS 316
Butt
joint
Laser Brazing with Active Cusil
Alloy
Laser Texturing
Machine Tools Laboratory

(a) (b) (c)
7.2
m
-21.1m -20.6m
2.7
m
0
50
100
150
200
250
300 500 800 1000
D
i
m
e
n
s
i
o
n
s

(

m
)
Scanning Velocity (mm/min)
Width
Depth
(a)
0
50
100
150
200
250
20 50 70 100
D
i
m
e
n
s
i
o
n

(

m
)
Laser Power (W)
Width
Depth
(b)
(c)
0
50
100
150
200
250
0.01 0.05 0.1 0.5
D
i
m
e
n
s
i
o
n

(

m
)
Pulse Width (ms)
Width
Depth
(d)
0
50
100
150
200
250
10 20 30 40
D
i
m
e
s
n
i
o
n

(

m
)
No. of Passes
Width
Depth
(e)
40
50
60
70
80
90
100
1 2 3
C
o
n
t
a
c
t

a
n
g
l
e

(
d
e
g
r
e
e
)
Reference
Surface
Laser
Textured
Surface
(f)
Results of sessile drop test

Machine Tools Laboratory
Micromachining Cell
Reverse Micro-EDM
Reverse micro-EDM
Fabrication of high aspect ratio micro-electrode arrays






Potential application in machining hole arrays via
micro-EDM/ECM
Machine Tools Laboratory
Micromachining Cell
Arrays Fabricated via R -EDM
Machine Tools Laboratory
Micromachining Cell
6x6 array
4x4 array
Measured
Contact
angle on
Reverse
Micro EDM
pattern is to
around 112
0

Reverse EDM of Ti6Al4V for Textured
Surfaces

Machine Tools Laboratory
Micromachining Cell
Hydrodynamic Nanopolishing
Applications of Nanopolished Surfaces
Optics (High power laser)
Military fields (Heat seeking missiles)
Electronics (Silicon wafers)
Industrial (Precision tools)
Nanopolishing Methods
Diamond Turning
Precision Grinding
Thermo-chemical Polishing
Laser-Beam Polishing
Ion Beam Polishing



Nanopolsihing
Hydrodynamic Polishing
Process
HDP Characteristics
Minute volume removing process
Insensitive to vibrations
Machining rate:
Capability of a particle
Number of particles
Quasi-deterministic
Profiled surface machining
capability
HDP Polishing Setup
Experimental Setup
Factors
Load (N) Abrasive
size (m)
Spindle
speed (rpm)
Stiffness
(shore A)
Roughness (m) Remarks
7.5 1 2400 90 0.0035 Optimum
7.5 0.05 3600 90 0.0193 Worst
Process Response
Machining using CNC turning machine
Spherical cavity on single crystal sapphire
Feed Rate and Depth of Cut while machining as low as 1m/rev
Conformal HDP of Single Crystal
Sapphire Cavity
52
Machined Sample Drawing:
Initial experiments indicate with reducing tool insert radius the surface
roughness reduces
Surface Roughness reduced by reducing the feed rate and doc

Machining and Conformal HDP of
Single Crystal Sapphire
53
Surface Roughness Data
( 0.05mm tool & 1m FR & DOC )
Region Sa (nm)
center 508.72
near center 566.099
near extrimity 412.2278947
extremity 446.1415
Average Sa 476.431
0
500
1000
1500
2000
center near center near
extremity
extremity
A
v
e
r
a
g
e


S
u
r
f
a
c
e


R
o
u
g
h
n
e
s
s
,


S
a


(
n
m
)
Feed Rate & DOC = 5um
Feed Rate & DOC = 3um
Feed Rate & DOC = 1um
Optimization of
Machining Process
54
S
a
= 1040nm S
a
= 265nm
Visibly low-crack surface
Conformal Hydrodynamic
Polishing Mechanism
55
Designed at Machine Tools Lab, IIT Bombay
Video
56
Surface Roughness reduction by upto 75%
Minimum Surface Roughness reached = 209 nanometers
Polishing Results
57
200
350
500
650
center near center near extrimity extremity
A
v
e
r
a
g
e

S
u
r
f
a
c
e

R
o
u
g
h
n
e
s
s
,

S
a

(
n
m
)
Pre-machined
Polishing by 0.06m
Micro-Crack free Surface
58
Cracks
Cracks
Cracks
Best Pre-machined Surface After Polishing
PROCESS SIMULATION
Machine Tools Laboratory

Fully Coupled Electromagneto-Thermo-
Mechanical Model for E.M. Forming in
COMSOL
Slide 5
Deformation profile
Radial Lorentz body
force
Slide 15
Model prediction error for the maximum deformation at tube center
- using coil C1 is less than 4% and
- using coil C2 is less than 12%

Shorter coil produces more peak deformation at the centre.
Preliminary simulation of in-line backward
flow forming process in Deform 3D
Physical Description of FE model
3D rigid-plastic FE model
Material flow
Longitudinal cross section of
the spun tube showed build up
and craters
Distribution of displacements in
axial direction
Negative displacement of
material under the rollers
Positive displacement of material
at the end of tube
Stress Distribution
64
Radial stress
Circumferential stress
Axial stress
Radial Ring Rolling Simulation in
Deform 3D
Machine Tools Laboratory

Results
Machine Tools Laboratory

Various Damage Mechanisms in
composite materials
18-Nov-11 67
Various mechanisms of damage in composite
laminates by [Talreja et al. (2006)]

Representative Volume Element
RVE)
18-Nov-11 68
1.Representative volume element is used to
predict various properties of the bulk
material
2.RVE is also used to predict initiation and
propagation of various damage mechanisms.
3.A micromechanics based software Digimat
is used for generation of RVE with periodic
boundary conditions.
4.ABAQUS is used to perform simulations.
Summary
Hybridization of existing tool-based
micromachining methods
Reconfigurable laser manufacturing
Arrayed microstructures for enhanced
productivity
Novel super-finishing method
Process simulation

Machine Tools Laboratory
Micromachining Cell
Acknowledgements
Prof. Suhas Joshi, Prof. K. Narasimhan, Prof.
Shreyes Melkote
Students
Sachin Mastud
Vijay Doiphode
Mahesh Teli
Prashant Kumar
Ishank
Yogesh Wagh
Vivek Varkal
Harshita
Pushkar

Machine Tools Laboratory
Micromachining Cell
Ramesh Singh, IIT Bombay
Questions?