Advanced engineering ceramics which are widely used as high strength refractory material for several industrial applications, always pose a challenging opportunity to machine them. Conventional methods of machining are difficult to shape them because of their high hardness and brittleness, while grinding is the only popular method to machine them, but shaping of ceramics in desired form is diff...

We present a low cost technique of direct machining of precision waveguide structures on metal blocks. The micro machine setup employs compact, precision numerically controlled (NC) stages to automate the machining process. Endmills are held in high speed pneumatic spindles, while other features are made by scraping (”broaching”) in repeated small passes. We can set up two endmills and three br...

To sustain in the modern era of rapid manufacturing development, it becomes necessary to generate complex shapes on materials which are highly temperature and corrosion resistant, hard to machine, and have high strength-toweight ratio. Generation of complex shapes on those materials using conventional machining processes ultimately affects surface finish, material removal rate, accuracy, cost, ...

Focused Ion Beam (FIB) is one of the important machining techniques to fabricate diamond sensors/detectors used for drug analysis, chemical analysis and bio-sensing applications. In-depth understanding of the high energy collision process and the residual damage induced along the trace of gallium ion could undoubtedly facilitate the development and improvement of performance of such devices thr...

This paper describes a combined mathematicalgraphical approach for optimum tool path planning in order to improve machining efficiency. A methodology has been used that stabilizes machining operations by adjusting material removal rate in pocket milling operations while keeping cutting forces within limits. This increases the life of cutting tool and reduces the risk of tool breakage, machining...

The deformation of aeronautical monolithic components due to CNC machining is a bottle-neck issue in the aviation industry. The residual stress releases and redistributes in the process of material removal, and the distortion of the monolithic component is generated. The traditional one-side machining method will produce oversize deformation. Based on the three-stage CNC machining method, the q...

Ultra-precision products which contain a micro-hole array have recently shown remarkable demand growth in many fields, especially in the semiconductor and display industries. Photoresist etching and electrochemical machining are widely known as precision methods for machining micro-holes with no residual stress and lower surface roughness on the fabricated products. The Invar shadow masks used ...

This paper presents an integrated machining error compensation method based on polynomial neural network (PNN) approach and inspection database of on-machine-measurement (OMM) system. To improve the accuracy of the OMM system, geometric errors of the CNC machining center and probing errors are compensated. Machining error distributions of a specimen workpiece are measured to obtain error compen...

Ultrasonic machining (USM) is a mechanical material removal process used to erode holes and cavities in hard or brittle work pieces by using shaped tools, high-frequency and an abrasive slurry. This paper addresses the concept and development of an expert system (ES) for hard and brittle material, such as glass, quartz, diamond, carbides, semi conducting materials, ceramic and graphite which ca...