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Microwave Drilling
Published in Amit Bansal, Hitesh Vasudev, Advances in Microwave Processing for Engineering Materials, 2023
Anurag Singh, Gaurav Kumar, Pranjal Gupta, Apurbba Kumar Sharma
Several nontraditional machining processes have emerged in the last few decades to deal with the limitations of conventional drilling. Processes, such as laser beam machining and electron beam machining, show excellent precision and accuracy. But most of these processes exhibit common limitations such as high initial setup cost, high operational and maintenance cost, low material removal rate (MRR) and high specific energy consumption [1]. Moreover, few processes are material-specific; for example, electrical discharge machining (EDM), electrochemical machining (ECM) and chemical machining (CHM) are generally restricted to metallic parts [2]. These limitations have motivated researchers to look for simpler, cheaper, versatile and energy-efficient alternatives. Microwave drilling is one such process being explored.
Sequential Laser and Electrical Discharge Machining
Published in Basil Kuriachen, Jose Mathew, Uday Shanker Dixit, Electric Discharge Hybrid-Machining Processes, 2022
P. S. Suvin, Ranjeet Kumar Sahu
Laser is an acronym for light amplification by stimulated emission of radiation. Using an optical lens, the laser beam can be focused. Further, this focused laser, owing to its high-power density in excess of 1MW/mm2 can be used for the removal of material through ablation. Laser power density will be of the order of ~107 W/cm2. Laser-beam machining uses a high heat energy coherent beam of light to remove a tiny bit of material in the form of debris from any metallic/non-metallic components through melting and vaporization. LBM is mainly used for the machining of holes in a precision manner.
Conventional and Advanced Manufacturing of Materials
Published in Ashutosh Kumar Dubey, Amartya Mukhopadhyay, Bikramjit Basu, Interdisciplinary Engineering Sciences, 2020
Ashutosh Kumar Dubey, Amartya Mukhopadhyay, Bikramjit Basu
Laser beam machining is another non-conventional process which uses a high power laser source. The laser−material interaction allows the metal to locally melt and vaporize (Figure 5.11). Based on the path traversed by the laser beam, the metal can be machined. The major process variable is the laser power. In order to avoid oxidation, the laser beam machining of metals are performed in an inert gas atmosphere.
A review on microholes formation in glass-based substrates by electrochemical discharge drilling for MEMS applications
Published in Machining Science and Technology, 2022
Tarlochan Singh, Julfekar Arab, Pradeep Dixit
Several methods are used to create microholes in the glass-based materials for microsystem application. Mechanical micro-machining includes abrasive jet machining and ultrasonic machining (Cheema et al., 2016; Cheema et al., 2015; Park et al., 2004). Thermal machining processes include laser beam machining in which the material is removed by ablation and evaporation (Hwang et al., 2004). All these processes can process materials at the microscale. However, there are certain limitations associated with each of these processes. Mechanical processes generally induce edge chipping during microholes formation. Laser machining is used to fabricate various microsystems devices. Similarly, chemical etching (wet and dry etching) is capable of producing the smallest dimensions, but the capital cost and maintenance cost are higher (Iliescu et al., 2008). Chemical etching requires a cleanroom fabrication lab, which costs more (Iliescu et al., 2007). The etch rate in chemical etching is very low (<5 μm/min). In recent years, the ECDM has emerged as a cost-effective and efficient alternative to other processes to machine nonconductive materials (Pawariya et al., 2019). The ECDM method is the hybrid technique that works on the ECM and EDM processes (Arab et al., 2020). The ECDM process offers advantages over other methods such as simple experimental setup, higher etch rate, good machined surface quality and ease in complex feature generation. The ECDM process has been used to machine various nonconductive materials such as quartz, ceramics, and glass fiber reinforced plastic (Singh and Dvivedi, 2016; Wüthrich and Fascio, 2005; Goud et al., 2016). Table 2 shows the pros and cons of different glass drilling processes.
Bayesian closed-loop robust process design considering model uncertainty and data quality
Published in IISE Transactions, 2020
Linhan Ouyang, Jianxiong Chen, Yizhong Ma, Chanseok Park, Jionghua (Judy) Jin
Laser beam machining is an advanced manufacturing process that can shape almost all engineering materials. The implementation and effectiveness of the proposed online optimization design approach is illustrated through an Nd:YLF laser beam micro-milling process shown in Figure 5 (left). There are three design variables (i.e., laser power (x1), scanning step (x2) and cutting speed (x3)), whose features are shown in Table 3. The output response y is the milling depth.