Micro Manufacturing
ME 686: Micro-manufacturing
Assignment 1
Study the effects of process parameters (speed, feed, depth of cut etc.) associated with SPDT for manufacturing of micro lens let arrays. Also find out the ranges of these process parameters and values of optimal process parameters.
Submitted by: Marmeek Kishor Kumar Kosambia (09010332)
Submitted to : Dr. S.N. Joshi
Date of Submission: 17/01/13
Introduction
A microlens array is composed of a series of micro lens distributed in a regular pattern and has been usedin a wide range of photonic products. A micro lens is a small lens, generally with a diameter less than a millimetre (mm) and often as small as 10 micrometers (µm). The small sizes of the lenses means that a simple design can give good optical quality but sometimes unwanted effects arise due to optical diffraction at the small features. A typical micro lens may be a single element with one plane surface and one spherical convex surface to refract the light. Because micro lenses are so small, the substrate that supports them is usually thicker than the lens and this has to be taken into account in the design. More sophisticated lenses may use aspherical surfaces and others may use several layers of optical material to achieve their design performance.Since surface roughness affects the performance of the lens, one needs to generate finely machined surface with minimum roughness
Single Point Diamond Turning machining is a technique which removes materials from a few microns to sub-micron level to achieve ductile mode machining on hard-to-machine materials such as electro less nickel plating, silicon, quartz, glass and ceramics with no subsurface defects. Such a machining process is able to achieve mirror surface finish of less than 10 nm and form error of less than 1um easily. If properly applied to a specific range of diamond turnable materials, the process is far superior to grinding and polishing where shape control is more difficult and processing
Assignment 1
Study the effects of process parameters (speed, feed, depth of cut etc.) associated with SPDT for manufacturing of micro lens let arrays. Also find out the ranges of these process parameters and values of optimal process parameters.
Submitted by: Marmeek Kishor Kumar Kosambia (09010332)
Submitted to : Dr. S.N. Joshi
Date of Submission: 17/01/13
Introduction
A microlens array is composed of a series of micro lens distributed in a regular pattern and has been usedin a wide range of photonic products. A micro lens is a small lens, generally with a diameter less than a millimetre (mm) and often as small as 10 micrometers (µm). The small sizes of the lenses means that a simple design can give good optical quality but sometimes unwanted effects arise due to optical diffraction at the small features. A typical micro lens may be a single element with one plane surface and one spherical convex surface to refract the light. Because micro lenses are so small, the substrate that supports them is usually thicker than the lens and this has to be taken into account in the design. More sophisticated lenses may use aspherical surfaces and others may use several layers of optical material to achieve their design performance.Since surface roughness affects the performance of the lens, one needs to generate finely machined surface with minimum roughness
Single Point Diamond Turning machining is a technique which removes materials from a few microns to sub-micron level to achieve ductile mode machining on hard-to-machine materials such as electro less nickel plating, silicon, quartz, glass and ceramics with no subsurface defects. Such a machining process is able to achieve mirror surface finish of less than 10 nm and form error of less than 1um easily. If properly applied to a specific range of diamond turnable materials, the process is far superior to grinding and polishing where shape control is more difficult and processing
References: 1. V.SainiD.SharmaS.KallaT.Chouhan, ‘Optimization of Process Parameters to Achieve Nano LevelSurface Quality on Polycarbonate’, Proceedings of the International Conference on Manufacturing Excellence, 2012 2. N.KhatriV.MishraR.G.V.Sarepaka, ‘Optimisation of process parameter in ultra-precisiondiamond turning of polycarbonate material’, International Journal of Computer Applications (0975 – 888) Volume 48– No.13, June 2012