MAPE- Blog on Micromachining

 

HA Topic - Blog on Micromachining

Div. - TY_ME_B_Batch_1

Group - 2 

Micromachining

[1]

What exactly is Micromachining ?

In today's high-tech engineering industry, the designer requirements of the component are strict, such as: Unusual structures of building materials (say, High strength, high temperature resistance, high durability, resistance to corrosion etc.). Complex 3D component (say, turbine blade). Small features (food processing filters and textile industries with a few micrometers such as hole diameter and thousands in numbers). Nano level is eliminated in complex geometries that can be achieved by any traditional methods (e.g., thousands of cooling holes moved in the turbine blade area, manufacture and removal of microfluidic channels in electrical and non-volatile materials (say, glass, quartz)., Clay vessels). ). Such features in part can only be achieved through improved production processes in general and particularly advanced mechanical processes.

Micromachining is the process of making very small parts with tools smaller than 0.015 inch in diameter and with just a few tenths of tolerance. Micromachining can create the smallest and most complex components needed in other applications, especially in the semiconductor and the medical industry. Equipment required for both sufficient spinning speed and strong cutting tools to produce multiplication and speed running speed. Micromachining tools may be as small as 0.001 inch wide (1/3 wide of human hair) to achieve the required precision and detail.

What Can Micromachining Do?

Mechanical micromachining or commonly known as micromachining is a manufacturing technology that involves the use of small mechanical tools with geometrically defined cutting edges in the output of devices or features with a minimum size of them at a micrometer distance. These components can be used in testing, redesigning large-scale processes to a lesser extent. The chip and microfluidics are two examples of micromachining applications.

Conventional mechanical processes, which use a lot of mechanical energy to extract large quantities of material from a working piece, are not suitable for getting miniaturized components. Various non-traditional operating systems (NTM), precision production technologies and micro-electromechanical systems (MEMS) are widely used to meet the ever-increasing demand for small products. In addition to these processes, mechanical-based manufacturing technology emerges as one of the most effective way to create complex 3-D features in a variety of materials including metals, polymers, composites and ceramics.

Micro-machining processes

The amount of material extracted locally by means of a small machine is small and the removal rates are usually very low (Table 1), the manufacture of small machinery is particularly suitable for the production of small structures and small parts. If the micro-machining process is set to the performance of large-scale operations, this is attempted because a very robust number and pay tolerance can be met. Depending on the accuracy achieved, these applications are often referred to as 'precision machine' or 'high precision machine'. When the amount of material removed becomes too small, a switch to nano-machining is made, which is an important branch of nanotechnology.

Table 1 : 

	nano-machining	micro-machining	macro-machining
size of machined area	1–105 μm2	1–105  mm2	1–105 cm2
volume removal in one machining  step	from 10-3  To  10-2 μm3	from 10-3  To  102 mm3	from 10-3  To  102 cm3
material removal rate	from 10-5  To  1 μm3  s−1	from 10-5 To  1 mm3 s−1	from 10-5  To  1 cm3s−1
relative figure error	from 10-5  To  10-3	from 10-7  To  10-5	from 10-5  To  10-3
surface roughness (Sa)	1–102 Å	1–102 nm	From 10-1 To  10 μm

Classification of Micro-machining processes

Micro-machining processes can be categorized according to the nature of the physical, chemical and mechanical removal process (Figure 1). While physical and chemical machinery is limited to certain systems, mechanical engineering is almost universal and has a long tradition. This is because a large class of engineering materials (metals, semiconductors, pottery, tempered glass, and plastics) can be processed and can be made into a wide variety of visual, electrical or mechanical applications. Minor machinery is further subdivided into cutting and cutting abrasives, with the following combining precision grinding and polishing and the former being dominated by diamond turning and milling.

The goal of micro-machining is to achieve the required precision in a single step of the machine without having to repeat the mechanical cycles and test slightly changing. Therefore, all parameters affecting the accuracy of the process should be identified and controlled as needed in order to achieve reliable given tolerance. Once this is achieved, the process is called 'deterministic'. Not all micro-machining processes determine the given tolerance set. By pushing the threshold of indeterminism into strong tolerance, an accurate engineer fights countless causes and effects as well as non-macro-machining effects.

Non-Traditional Machining (NTM) processes

Non-Tradition Machining (NTM) processes are newly developed material removal processes that utilize various forms of energy in their direct form to remove excess material from workpiece in order to get desired shape, surface finish and tolerance. Such processes are also called Unconventional Machining Processes or Advanced Machining Processes (AMPs). They can be used for generating complicated features as well as to obtain quality finished surface. In rare cases, they can also be for bulk removal purpose. Few NTM processes are enlisted below.

• Abrasive Jet Machining (AJM)

• Abrasive Water Jet Machining (AWJM)

• Ultrasonic Machining (USM)

• Chemical Machining (CHM)

• Electro-Chemical Machining (ECM)

• Electro Discharge Machining (EDM)

• Laser Beam Machining (LBM)

• Electron Beam Machining (EBM)

• Plasma Arc Machining (PAM)

• Ion Beam Machining (IBM)

Abrasive jet machining (AJM)

(AJM) is one of the modern mechanical systems based on mechanical power where the key is to remove the controlled cutting action caused by the impact of a high-speed aircraft (100 - 300m / s) of abrasive grains accelerated by dehumidified gas. 10 - 15bar). The microphone directs the gliding plane in a controlled manner in the work area. When this high-speed explosive jet is made to insert a working area somewhere from the correct stop range (SOD), it erodes what is essentially a small cut and is sometimes aided by a fracture.

Abrasive Jet Machining (AJM) is one of the most powerful mechanical systems in which the device removes the controlled cutting action caused by the impact of a high-speed aircraft (100 - 300m / s) of abrasive grids accelerated by moisture removal. compressed gas (10 - 15bar). The microphone directs the gliding plane in a controlled manner in the work area. When this high-speed explosive jet is made to place the operating area somewhere from the correct stop range (SOD), it erodes what is essentially a small cut and is sometimes aided by a fracture.

In Abrasive Jet Machining (AJM), air is usually taken directly from the atmosphere, purified and compressed at high pressure with the help of a compressor. Loose particles with pre-defined medium sizes are mixed with the compressed gas in a certain component (mixing ratio) and the mixture is allowed to beat the jet operation at a certain incident angle at very high speeds. The pipe converts the hydraulic force (pressure) of the jet-abrasive mixture into kinetic (velocity) forces. After the cutting operation, the grits leave the machine area, and are then collected and disposed of safely (usually, abrasive grits cannot be reused as the grits lose sharpness after the first impact).

AJM can effectively cut solid and breakable materials, and thus can be used for drilling, cutting, tearing, trimming, cleaning, and decorating. However, they are not suitable for soft and ductile materials, such as plastic, foam, etc., because explosive particles are often embedded in the work surface which interferes with cutting quality. Although the AJM process is noisy and less reliable, it can produce a surface area of ​​less than 1µm, if properly controlled.

Principle of AJM

Fine explosive particles with high kinetic energy (KE) beat the angles and remove the material in the form of micro / nano-chips.

If the KE of the explosive particles is high enough, it will remove the material by shear modification in the event of ductile workpiece material and by fracture breakage if the workpiece material is brittle.

Holes up to 66 μm depth can be drilled without the use of special techniques. Micro burrs are clearly visible. This process is also helpful in producing small holes.

Laser Beam Machining (LBM)

Laser beam machining is an unusual method of operation when the operation is done with laser light. The laser lamp has a high temperature in the workplace, due to the high temperature the working object melts. The process used heat energy to remove objects from the metal surface.

Terms of service:

Like high-speed electron beams, the laser beam is also capable of producing very high power densities. The laser is a very coherent line (in space and space) of radiation with wavelengths ranging from 0.1 µm to 70 µm. However, the operating power requirement limits the useful wavelength range to 0.4-0.6 µm. Because laser radiation is fully compliant and monochromatic, it can focus on very small scales and can produce up to 107 W / mm². To improve high strength, a pulsed ruby ​​laser is usually used. The continuous CO2-N2 laser has also been successfully used in mechanical operation.

The integrated xenon flash tube is placed next to the ruby ​​rod and the inner surface of the vessel walls is made more transparent so that high light falls on the ruby ​​rod to be used for pumping. The capacitor is charged and a very high voltage is applied to the starting electrode to initiate light. The extracted laser beam is centered on the lens system and the focused beam meets the working surface, removing a small portion of the material by evaporation and emission at high speed. A very small fraction of the molten metal evaporates so rapidly that a high mechanical pressure is produced, releasing a large portion of the liquid metal. Since the energy emitted by the flash tube is far greater than the energy emitted by the laser head in the form of a laser beam, the system must be properly cooled.

The efficiency of the LBM process is very low - about 0.3-0.5%. The typical laser output power is 20 J and the average heart rate is 1 milliseconds. The maximum strength reaches a value of 20,000 W. Beam separation is approximately 2 x 103 rad, and, using a lens with a focal length of 25 mm, the area width is 50 μm.

Like an electron beam, a laser beam is used to excavate microholes and to cut very small gaps. Holes up to 250 µm in diameter can be easily drilled with a laser. The maximum accuracy is ± 0.025 mm. When the thickness of the workpiece is more than 0.25 mm, a taper of 0.05 mm mm is visible.

                  

        Alongside NTM systems such as Micro-electromechanical Systems (MEMS) systems are widely used in semiconductor industries such as integrated circuit construction (IC), chips, etc. These processes require a strong work environment to produce very small products. Many of these processes use controlled chemical reactions to extract material from a working piece. To date the use of MEMS systems is restricted mainly to the electronics industry due to the large number of issues and the slow process.

                  Accurate production processes are generally well established and those processes can be modified to produce a mirror space of less than 20nm. Another basic advantage is that these processes can easily incorporate very large components. Basically, conventional precision machining processes focus on producing a highly finished area regardless of part size.

 

Prominent Applications of Micromachining

Two micromachining applications that have received widespread use in automobiles are accelerometer devices (especially airbag transmission sensors) and pressure sensors in automotive, industrial, and biomedical markets. Both are consistent with the definition of MEMS devices with moving or flexible structures. Accelerometer devices usually use capacitive sensing to measure the power generated between a moving and an immovable surface.

 

 

 

 

 

 

 

 

 

The Future - Transition from Micromachining to NanoMachining

 

• Nano  is  the  buzzword  of  the  moment,  which  demands  refinement  in micromachining resulting in the evolution of nanomachining.

•  Thus  the  transition  from  Micro Electro-Mechanical Systems  (MEMS)  to Nano-Electro-Mechanical Systems (NEMS) will take place.

• The smallest features that have been fabricated using lithography are only a few tenths of a nanometer in dimension.

•  Nanomachining has been used by a number  of groups to fabricate quantum devices such as single electron transistors (SETs) and metal-oxide junctions

 

 

REFERENCES
[1] https://www.citrogene.com/what-is-micromachining/

[2] https://www.ipme.ru/e-journals/RAMS/no_13012/06_cardoso.pdf

[3] https://www.researchgate.net/figure/A-brief-classification-of-the-micromanufacturing-processes_fig1_299180402

[4] https://royalsocietypublishing.org/doi/pdf/10.1098/rsta.2011.0056

[5] https://learnmechanical.com/abrasive-jet-machining/

[6] https://www.mech4study.com/2017/03/laser-beam-machining-principle-working-equipment-application-advantages-and-disadvantages.html

 

 

 

Thank you….!

Latest Trends in Reciprocating Compressor

Fig.1. RECIPROCATING COMPRESSOR

INTRODUCTION :

Fig.2. Cross-sectional View

Reciprocating compressors are widely used in the manufacture of petroleum and chemicals, including gas compression and natural gas transportation. Additionally, reciprocating compressors find applications in an array of industrial sectors, including chemicals, oil and gas, metal processing, refrigeration, power generation, and pharmaceutical. In recent years, shareholders in the reciprocating compressor market are anticipated to focus on enhancing the machine's durability, narrowing gas flow, assisting in rotation, and managing heat efficiently.The major factor driving the growth of the reciprocating compressors components market is the increasing adoption of reciprocating compressors in the iron and steel production process. The steel industry has been experiencing considerable growth in terms of its production capacity over the past decade.

This growth is because of the growing demand for steel from the developing nations in the world. The increasing adoption of reciprocating compressors will further boost the growth of the reciprocating compressor components market. However, the high cost of installation of reciprocating compressors is significantly high which is expected to impede the demand of the reciprocating compressor components market.

In addition, the rising cost due to the maintenance of different components such as crankshaft, connecting rod, crosshead, piston rod, and rings, packing rings or seal rings, control valves, suction unloaders, and clearance pockets is likely to hinder the global reciprocating compressor components market during the forecast period.

            The increasing demand from refinery and CNG & LNG transport and storage plants are the significant factors driving the growth of the reciprocating compressors market. However, the fraudulent imitation of compressor designs and the intense price competition are the major factors that may restrain the growth of the reciprocating compressors market. Additionally, the reciprocating compressors offer excellent features which include high ability and efficiency to produce both high power and pressure, thereby boosting the growth of the global reciprocating compressors market.

How Compressor Work?

            The basic working principle of gas or air compressor can be easily understood. Basically, it works by changing the volume of the gas or air. It uses a piston or diffuser to increase the pressure of the working fluid. When the working fluid enters into a diffuser, it changes the speed of the fluid into pressure energy.
In this way, a compressor compresses the gas or air. After the compression process, the compressed air is transformed into a storage tank. Many industries have used compressors to increase production, which has led to the development of many new industries. Nowadays, many companies manufacture and supply air compressors to different industries. The manufacturing of these machines was initially done using wood, but now many modern techniques and materials are being used to manufacture them. Many countries are using air compressors to their advantage. They are making use of these machines to save their precious time, energy, and money.

Types of Air Compressor 

Fig.3. TYPES OF AIR COMPRESSOR

WHAT ARE RECIPROCATING COMPRESSORS? 

                 A reciprocating or piston compressor is a machine that can distribute a limited amount of gas or liquid at high speeds. Using a piston to compress the grip chamber, the contents are then released under high pressure, which effectively applies them to the intended application. This delivery method offers reduced energy losses compared to other types of compressors, as very little excess heat is produced during operation. Two main types of this compressor are classified as continuous flow outflow or intermediate discharge. Continuous flow is achieved by the same design but with the use of two or more cylinders operating close to each other. It is often associated with its use in supplying gasoline to a car engine. A reciprocating air compressor is a positive-displacement compressor that uses a crankshaft-driven piston and cylinder to compress the air.  A two-stage compressor includes an additional step where the air is compressed by a second, smaller piston to a pressure of up to 175 PSI.

PET AIR COMPRESSOR SYSTEMS:-   

         Another industry that has seen continuous growth worldwide is polyethylene terephthalate, or PET as it is commonly abbreviated. The manufacture of air-conditioned plastic bottles in containers containing molten PET has become a major industry, thanks to the large number of plastic bottles used daily and in all parts of the world. The modern PET industry has seen great improvement in compressors in recent years, with new designs reaching higher production speed using lower pressure, more efficient beat, and development that reduces energy requirements and therefore has lower running costs. Another feature that reduces operating costs is the lifespan of the components used in compressor construction. New materials used in many moving parts and seals also provide additional durability in the overall quality. This not only allows for fewer scheduled services but also reduces overheads at professional costs.

Fig.3. RECIPROCATING COMPRESSOR

With such a large industry now in existence, there are many options around the type of compressor that can be used in a production system. This gives businesses a lot to consider when setting up a new manufacturing industry and highlights not only how big the industry has become, but also how the compressor market is developing.

COMPRESSOR IN NATURAL GAS STATIONS:-

             As the natural gas industry has developed safer working environments, the number of companies seeking to exploit this advanced market has grown exponentially in recent years. Large industrial compressors have become an important part of this development as they are used in both storage and transportation of gas. As new technologies were applied to these compressors, they not only became more reliable but also provided additional functionality such as vibration analysis and increased control over flow rates. These new systems can not only bring more control, but also work longer between repair tests, with some statistics suggesting that some types of compressors require fixed repair checks up to ten times higher than piston compressors. Another major service area that offers benefits to repetitive compressors is the state of easy maintenance with new designs, which allows for faster service and therefore a reduction in operating conditions.

Fig.4. A compressor in Gas Stations

Advantages	Disadvantages
These are easy to maintain.	These compressors produce high noise.
These are best for applications that need high pressure.	It is highly vibrating equipment.
Highly efficient and flexible.	It has a large size.
It has a simple design.	These pumps can’t deliver constant flow.

MAINTENANCE

Although the piston compressor requires a much smaller adjustment than the diaphragm compressor, it is still important work to be done to extend the life of the machine and prevent any major failures prematurely. Due to the variety of compressor types and the many nuances of setting up a well-designed system between different workloads, it is possible to write a book about the compressor service routine. One important thing to keep in mind when servicing these condensers is that whenever valves, pistons, or other components are replaced, it is always advisable to replace nearby components such as gas seals, springs, and anchors at the same time. Because the compressor has moving parts that are subjected to high pressure when operating, the signals need to be handled with the utmost care. Although much progress has been made in these areas in recent years, they still need attention.

 

SHORT-TERM INVESTMENT FOR LONG-TERM SAVINGS-:

Although reciprocating compressors offer many benefits to businesses, many of them are based on high performance or may specify specific industry needs. It is therefore wrong to degrade other types of compressors in the market, and it is always a good idea to compare your needs against the related compatibility and weaknesses provided by each design. What the reciprocal compressor offers, however, is an energy-saving unit with incomparable reliability, albeit at a high cost of purchase and installation.With a product growing rapidly in popularity, there is a large amount of continuous investment that continues to advance the development of this compressor. It is impossible to say what the future holds for the technology of the future, but at the moment it is clear that the main focus of many companies is the use of a compatible compressor due to the long term we offer. With so many switching companies manufacturing parts on site, it is unlikely that there will be a shortage of support for these machines for too long, and until something better comes to market, it looks like this compressor will continue to grow from strength to strength.

Fig.5.Industrial Air Compressor Market

Impact of COVID-19 on the Market :

       The increasing use of Reciprocating Compressors in Vertical, Horizontal, and other industries drives the growth of the Reciprocating Compressors market worldwide. The Global “Reciprocating Compressors Market” is expected to grow at a steady pace during the forecast period 2021-2027, the Reciprocating Compressors Market report provides details on the latest trends. saw the highest demand, leading regions, and applications. Provides high-quality and comprehensive information on the features, challenges, and opportunities that will define market growth in 2021-2027, COVID-19 can affect the global economy in three main ways: by directly affecting production and demand, by creating supply chain and market disruption, and its financial impact on financial firms and markets.

The main purpose of this report is to provide information on the post-COVID-19 impact that will help market players in the industry to evaluate their business practices. Also, this report covers market segregation by major market consumers, types, applications/end users, and countries (North America, East Asia, Europe, South Asia, Southeast Asia, Middle East, Africa, Oceania, and South America).

The market for Global Reciprocating Compressors is expected to rise sharply during the forecast period, between 2021 and 2026. By 2020, the market is growing at a rapid pace and with the increasing adoption of strategies by key players, the market is expected to grow. ascend above the proposed atmosphere.

           The global market for Reciprocating Compressors is projected at 8793.9 Million USD by 2020 and will grow by a CAGR of 8.34% from 2020 to 2027, based on a recently published research report.

Reciprocating Compressor Components Market: Regional Outlook

The Asia Pacific is the leader in the consumption of the reciprocating compressor components in the global market. This is attributed to rapid growth in the industrial, electronics, and manufacturing activities in the region in past few years. China has become the electronics manufacturing hub of the world which has created huge opportunities for the reciprocating compressor components manufacturers.

Europe, led by rapid industrialization has also contributed significantly to the global market. However, the outbreak of the coronavirus has put some barriers on the compressor components market such as economic uncertainty, disturbed supply chain, and an insufficient inventory which has caused latency in the market. Although, the market is poised to rebound in long run to create significant opportunities.

Major Market Player Included in this Report are:

- Ariel Corporation

- Atlas Copco

- Burckhardt Compression AG

- Gardner Denver, Inc.

- Howden Group

- IHI Rotating Machinery Engineering Co., Ltd.

- KAESER KOMPRESSOREN

- MIKUNI KIKAI KOGYO CO., LTD.

- Siemens

- The Japan Steel Works, LTD.

References:

[1]https://www.wboc.com/story/45092187/Reciprocating-Compressors-Market.

[2]https://www.marketwatch.com/press-release/reciprocating-compressor-market-insights-by-latest-trends-and-top-companies-revenue-forecast-demand-forecast-to-2026-2021-12-15

[3]https://www.gminsights.com/blogs/industrial-air-compressor-top-trends

[4]https://www.researchandmarkets.com/reports/5235757/reciprocating-compressors-market-global-industry