For more information: 202-994-6749
MAE SEMINAR SERIES
Tuesday, September 13, 2005
Phillips Hall 6th Floor Conference
Room #640; 2:30pm
Recent Investigations On
Micromachining In Institute Of Manufacturing Technology At Warsaw
University Of Technology
The need for complex
and accurate three-dimensional (3-D) micro components is increasing
rapidly for many industrial and consumer products.
Electrochemical machining process has the potential of generating
desired crack-free and stress-free surfaces of micro components.
However, it is necessary to modify the existing ECM process for
reducing the interelectrode gap (it improved accuracy and higher
localized electrochemical dissolution for obtain smaller feature
size). The presentation reports a newly developed Pulse
Electrochemical Micro Machining (ECMM) process for generating complex
3-D micro components of high accuracy. A mathematical model has
been developed and experimentally verified using a recently designed
and built ECMM system. The application of the proposed method has
been illustrated by machining complex 3-D cavities. The efficiency of
these techniques can be improved by using a hybrid process of
electrochemical dissolution assisted by laser heating. The problems and
results of experimental investigation of laser electrochemical
micromachining (LECMM) process are also discussed. The simulation and
experiments show that the use of passivating electrolytes and is
beneficial in achieving high accuracy of micro features by increasing
the localization of dissolution in shaping processes. In last part of
presentation a study of Rotary Electrical Discharge
Machining/Micromachining (REDM and REDMM) process is presented. In REDM
simple shaped cylindrical electrodes are used to generate 3D complex
shapes. The theoretical model of machining process that takes into
consideration the effect of tool electrode wear on machined surface
profile is described. The software for computer simulation of REDM has
been developed. Results of computer simulation have been confirmed in
experimental practice. The simulation model for NC contouring REDM may
also be applied to solving numerical control problems and optimization
of tool electrode path.
Jerzy Kozak is a full
tenured professor of Manufacturing Technology at the Warsaw University
of Technology (WUT). He was educated at WUT (Aeronautical and Power
Engineering Faculty), where he received a M.Sc. in 1961, a Ph.D. in
1969 and a D.Sc.(Habilitation) in 1977. From 1979 to 1982, he served as
scientific director of the Institute of Aviation in Warsaw, and from
1990 to 1994 and from 2000 to 2002 he was a visiting professor at the
University of Nebraska -Lincoln (USA). The research interests of Prof.
Kozak include manufacturing science and engineering, especially the
non-traditional machining processes and micromachining and their
applications in industries. His many achievements, reflected in
numerous scholarly papers in journals and periodicals, papers in
referred proceedings and 7 books, include mathematical models,
investigations and simulation software for high-rate Electrochemical
Machining (ECM), Pulse ECM, and Micro PECM, optimization of the
ECM/PECM processes, design of ECM electrode -tools, and investigation
of Micro EDM and Wire Electrical Discharge Machining (WEDM) of advanced
ceramics, metal matrix composites and polycrystalline diamond. Other
research activity includes non-Newtonian flow characteristics and
simulation in Abrasive Flow Machining, electrochemical machining with
laser assistance and abrasive hybrid electrical machining processes.