README.md 2.26 KB
Newer Older
Neil Gershenfeld's avatar
Neil Gershenfeld committed
1 2
# microcutting

Neil Gershenfeld's avatar
Neil Gershenfeld committed
3 4
Comparison of micro-waterjet, laser, EDM, NC, ... cutting

Sam Calisch's avatar
Sam Calisch committed
5 6
## micro-waterjet
### MicroMAX at OMAX Demo Lab - https://www.omax.com/omax-waterjet/micromax
Peter Liu's avatar
Peter Liu committed
7
Nozzle: 7/15 MAXJET5 Minijet Nozzle with 0.007" ID diamond orifice and 0.015" Roctec 500 mixing tube
Peter Liu's avatar
Peter Liu committed
8

Peter Liu's avatar
Peter Liu committed
9
Abrasive: 240 mesh Barton HPX garnet with a mean particle size of 60 um at a flow rate of 0.12 lb/min
Peter Liu's avatar
Peter Liu committed
10 11 12 13 14 15

Pressure: 50 ~ 55 ksi

Cutting time: 3.1 min


Sam Calisch's avatar
Sam Calisch committed
16
## solid-state laser micromachining
Prashant Patil's avatar
Prashant Patil committed
17
<!-- (picture of machine, cost of machine, machining time, picture before and after post-processing) -->
Neil Gershenfeld's avatar
Neil Gershenfeld committed
18

Sam Calisch's avatar
Sam Calisch committed
19
## ultrafast laser micromachining
Neil Gershenfeld's avatar
Neil Gershenfeld committed
20

Sam Calisch's avatar
Sam Calisch committed
21
## EDM
Neil Gershenfeld's avatar
Neil Gershenfeld committed
22

Will Langford's avatar
Will Langford committed
23
### Full-scale Toolpathing
Will Langford's avatar
Will Langford committed
24 25 26

We toolpathed the microspline part at the full ~2" long scale. This would be cut from a stack of six sheets of 0.03125" thick brass layered on top of a 1/16" thick piece of steel. We added slits in the frame to avoid pre-drilling any holes. We also removed all of the tabs. This may prove to be a bad idea but it allows us to get a sense of the speed of Wire-EDM vs uAWG without having to do a lot of pre-processing. The total path length of the full scale toolpath is 52.5 inches. With an expected cut speed of at most 0.22 inches/minute, the expected cut time is approximately 4 hours.  

Will Langford's avatar
Will Langford committed
27 28 29 30
### 1/3-scale Testing

Given the long machining time, we ultimately decided to do a 1/3-scale test cut from a stack of 0.01" brass sandwiched between 0.25" aluminum. The perimeter of this toolpath measures 17.5 inches. With an expected cut speed of 0.18 inches/minute, the expected cut time is just about 100 minutes or 1 hr 40 mins.

Neil Gershenfeld's avatar
wip  
Neil Gershenfeld committed
31
## [Micromachining using Zund G-3 L-2500](Zund/README.md)
Sam Calisch's avatar
Sam Calisch committed
32

Sam Calisch's avatar
Sam Calisch committed
33 34

## [Fablight fiber laser](http://cba.mit.edu/tools/display/?type=tool&id=fablight_3000_laser_cutter)
Sara Falcone's avatar
Sara Falcone committed
35

Sara Falcone's avatar
Sara Falcone committed
36
Machining time: ~5 min
Sara Falcone's avatar
Sara Falcone committed
37

Sara Falcone's avatar
Sara Falcone committed
38
Cost of machine: sheet only machine with the 3000 laser is around $80,000, and the tube & sheet is around $90,000
Sara Falcone's avatar
Sara Falcone committed
39 40 41 42 43 44 45

Machine settings:

![Fablight settings](../images/Fablight_settings.jpg)

Sample photos:

Sara Falcone's avatar
Sara Falcone committed
46 47 48 49 50 51
![fablight 1](../images/Fablight_01.jpg)

![fablight 3](../images/Fablight_03.JPG)

![fablight 5](../images/Fablight_05.JPG)

Sara Falcone's avatar
Sara Falcone committed
52 53
After burr removal 

Sara Falcone's avatar
Sara Falcone committed
54
![fablight 6](../images/Fablight_06.jpg)
Sara Falcone's avatar
Sara Falcone committed
55

Sara Falcone's avatar
Sara Falcone committed
56 57
The brown seen on the edges of the piece are burn marks where the machine cut. 

Sara Falcone's avatar
Sara Falcone committed
58
![fablight 7](../images/Fablight_7.JPG)
Sara Falcone's avatar
Sara Falcone committed
59

Sara Falcone's avatar
Sara Falcone committed
60 61
![fablight 8](../images/Fablight_08.JPG)

Neil Gershenfeld's avatar
wip  
Neil Gershenfeld committed
62
# ...