NANOFINISHING OF SHAFTS FOR ULTRA HIGH SPEED GAS BEARINGS

Objective:
To develop a novel nanofinishing process and develop setup for enhancing the performance of gas bearing-shaft combination and also develop suitable media.

Benefits:
Friction, starting torque and wear are considerably reduced. Better power output with reduced power losses. Improved reliability and fatigue life of the component. Improved load bearing surface area of the component by better surface finish.

Cad Model

Complete view of MAF Setup with D.C. supplies on both sides

Maxwell Result for Electromagnet

Simulation Results for electromagnet

0.2

Working Gap (mm)

0

Magnetic flux variation with different in currents and voltages

0.25

0.18

Magnetic Flux Intensity in Tesla

0.16

Working Gap (in mm)

0

8.5
0.14

0.2

Magnetic Flux Intensity in Tesla

8.5
0.15

0.12

0.1

0.08

0.1

0.06

0.04

0.05

0.02

0 20 25 30 35 40 45

Conclusion

Current (in A)

Voltage (in V)

The MAF setup has been tested and was found to work satisfactorily. High level of surface finish (of the order of nano scale). Better and uniform form geometry & Improvement in surface integrity.

Electrode diameter prediction for Block EDG Process

300

Low energy level

250 50uJ 60uJ 72uJ

Time (min.)

200

150

100

High energy level

500uJ 720uJ 2000uJ

50

0 0.0

0.1

0.2

0.3

0.4

0.5

0.6

Volume (cu. mm)

ED-milling of slots on hard materials

S. No. 1 2 3 4 Parameters Energy (J) Feed (m/min) Speed (rpm) Aspect ratio Range of values 500 and 2000 600 to 3600 100 to 800 0.5, 1.0, 1.5 and 2.0

80 80 70 70 60 60 50 50

100 rpm 500 rpm 800 rpm 1000 rpm 1500 rpm

Time

40 40 30 30 20 20 10 10 0

2000J

500J

10

20

30

40

50

60

70

80

Feed

The AFM is one of the foremost tools for imaging, measuring and manipulating matter at the nanoscale. FIB is used to carve AFM cantilever in-order to increase its reach and thus enhancing its ability. Such AFM tips can be used to check nano-flatness of LCD and TFT monitors.

At Resonance

No Resonance

At Resonance

Several pillars of Carbon, Tungsten and Platinum were deposited using FIB/FEBCVD with diameter ranging from 80-500 nm, height from 10-45 m and aspectratio of 80-240 and their vibrational aptitude was checked under precursor/no-precursor gas atmosphere and Youngs modulus was calculated. E-beam grown Carbon pillar with diameter 180 nm, height 21.4 m, resonance frequency as 422 kHz and Youngs modulus was calculated as 135.5 GPa.
300

25

450

Resonant Frequency (kHz)

Young's Modulus (GPa)

400

d=433 nm L=33.78 m

250

Spring Constant (x 10-3 N/m)

Resonant frequency for Carbon 3 assuming density =2300 Kg/m Linear Fit

Range of Young's Modulus of bulk DLC 165-210 GPa Experimental Young's Modulus of Carbon 3 assuming Density = 2300 Kg/m

20

Spring constant of Carbon assuming perfect cylinder Linear Fit d = 433 nm L = 33.78 m

200

15

350

Slope = 1.1975 kHz m

d = 318 nm L = 31.24 m d = 279 nm L = 36.17 m

d=318 nm L=31.24 m

150

300

d = 279 nm L = 36.17 m

10

d = 318 nm L = 31.24 m

d = 433 nm L = 33.78 m

Slope 2.467 x 10 N/m

5

10

100

250

d=279 nm L=36.17 m
50 200 250 300 350 400

0 0 2 4 6 8 10

200

250

300

350

400

d/L2 (m-1)

d/L2 (m-1)

4 3 -13 d /L (x10 m)

290 Full Area Scan Reduced Area Scan

302 300 Full Area Scan with Precurssor Gas ON Linear Fit of the Graph

Resonant Frequency (kHz)

Resonant Frequency (kHz)

285 Energy = 5.0 keV Current = 0.4 nA

Slope=3.08x10 kHz/s
-3

280

Energy = 10.0 keV Energy = 10.0 keV Current = 0.54 nA Current = 0.54 nA 275
Slope=2.18x10 kHz/s Slope=-0.394x10 kHz/s
-3 -3

Mass accumulation rate for FAS1 ~ 120 ag/s, for FAS2 ~ 90 ag/s and for RAS ~ 4 ag/s

298 296 294 292 290 288 286 284 -0.5 Initial Length of Carbon Pillar = 36.17 m Initial Diameter of Carbon Pillar = 279 nm 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 Energy = 5.0 keV Current = 0.4 nA

With precursor gas

Slope = 3.91x10-3 kHz/s

Mass accumulation rate for FAS ~ 162 ag/s

270

Without precursor gas

Initial Length of Carbon Pillar = 36.17 m Initial Diameter of Carbon Pillar = 279 nm

265 0 1 2 3 4 5 6 7 8 9 10 11 12

Irradiation Time (x1000 seconds)

Irradiation Time (x1000 seconds)

600 Full Area Scan Reduced Area Scan

590 Full Area Scan 580 Reduced Area Scan

Resonant Frequency (kHz)

Resonant Frequency (kHz)

590

Slope = 16.74x10-3 kHz/s

Slope = -9.56x10-3 kHz/s

580

570 Energy = 5.0 keV Current = 0.4 nA 560 Initial Length of Carbon Pillar = 19.19 m Initial Diameter of Carbon Pillar = 158 nm 0.0 0.5 1.0 1.5 2.0 2.5 3.0

Mass accumulation rate for FAS ~ 50 ag/s and for RAS ~ 8 ag/s

Slope = -21.19x10-3 kHz/s Slope = 19.68x10-3 kHz/s

570

560

550 Energy = 5.0 keV Current = 0.4 nA 540

Without precursor gas

3.5 4.0 4.5

With precursor gas

Mass accumulation rate for FAS ~ 70 ag/s and for RAS ~ 20 ag/s

Initial Length of Carbon Pillar = 19.19 m Initial Diameter of Carbon Pillar = 158 nm 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

530

Irradiation Time (x1000 seconds)

Irradiation Time (x1000 seconds)

Literature review on AFM Media

Medium

Most Important & Critical Component

Media flow
Viscoelastic Polymer with special rheological properties

direction

Gear teeth

Fine Abrasive Particles

PRESSURE
CARRIER MEDIA

WORKPIECE
Schematic diagram of Forces acting on a single grain in Abrasive Flow Machining

ABRASIVE GRAIN AXIAL FORCE (Fa)

Present status of the proposed work

RADIAL FORCE (FR)

Idea and concept of FR-AFM

Better finishing capabilities of AFM
Finishing of 2-D and 3D bend Pipes

Flexible Abrasive Flow Machining (F-AFM)

Advantages of rotating tool in various Machining and finishing process

Drill-bit assisted RAFF

Flexible Rotary Abrasive Flow Machining (FR-AFM)

Possible Flow of media

RAFF set-up

Abrasive flow mechanism

Tabletop pin on Disk Machine

-Spindle: 200 ~ 2000 rpm - Disk Size: 70 ~ 100 mm -Load : Static Weight 1 ~10N -Measurement: 360 x 300 x 240 - 0.5 g Sensitive

FRP-joining of girders

Two girders were joined in Tconfiguration with the help of high strength and high stiffness glass fiber tow wetted in epoxy resin