NDLI: Laminated fabrication of micro-stepped gear mold based on WEDM and thermal diffusion welding

Content Provider	Springer Nature Link
Author	Zhong, Jin ming Wu, Xiao yu Xu, Bin Li, Ji bin Luo, Feng Cheng, Rong Ruan, Shuang chen
Copyright Year	2015
Abstract	This paper presents a method of micro-double-staged laminated object manufacturing (micro-DLOM) for fabricating three-dimensional (3D) micro-molds and verifies its feasibility of fabricating of micro-stepped gear molds. First, under the action of 10 μs pulse width, 40 μs pulse interval, 0.28 Å wire-cutting current, and 60 V discharge voltage, a 100-μm-thick Cu foil is cut by wire electrical discharge machining (WEDM) to obtain a multilayer two-dimensional (2D) microstructure. Under the technological parameters of 850 °C thermal diffusion temperature, 10 h thermal diffusion time, and 1.0 N/mm2 pressure, the multilayer Cu 2D microstructure is then connected by vacuum-pressure thermal diffusion welding to fit the gear molds with two- and three-stage steps. Finally, on the basis of ultrasonic powder molding, two- and three-stage step plastic gears are respectively obtained. Compared with the ultraviolet lithography (UV-LIGA) process, the new process can fabricate complicated 3D microstructure with free-form surfaces; compared with the femtosecond laser-layering flat-scanning ablation process, the new process cuts only 2D microstructure of each layer with high processing efficiency; and compared with the micro-electrical discharge machining (EDM) process, the new process omits the step of microelectrode fabrication. Moreover, because there is no loss in the course of the microelectrode process, micro-molds in which the depth-to-width ratio is beyond limitation can be fabricated.
Starting Page	1233
Ending Page	1240
Page Count	8
File Format	PDF
ISSN	02683768
Journal	The International Journal of Advanced Manufacturing Technology
Volume Number	78
Issue Number	5-8
e-ISSN	14333015
Language	English
Publisher	Springer London
Publisher Date	2015-01-07
Publisher Place	London
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	3D microstructure Micro-DLOM WEDM Vacuum-pressure thermal diffusion welding Industrial and Production Engineering Production/Logistics/Supply Chain Mechanical Engineering Computer-Aided Engineering (CAD, CAE) and Design
Content Type	Text
Resource Type	Article
Subject	Industrial and Manufacturing Engineering Control and Systems Engineering Mechanical Engineering Computer Science Applications Software

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