Featured Research

from universities, journals, and other organizations

The best cut for machining

Date:
October 24, 2013
Source:
The Agency for Science, Technology and Research (A*STAR)
Summary:
A new and verified computer model improves the machining of nanoscale semiconductor parts for the electronics industry.

Conventional machine cutting of brittle materials can result in chipping and fracturing (left), but vibration-assisted machining with the correct depth of cut produces a chip-free, mirror-like surface (right).
Credit: 2013 A*STAR Singapore Institute of Manufacturing Technology

A new and verified computer model improves the machining of nanoscale semiconductor parts for the electronics industry

Brittle materials such as silicon and ceramics are used extensively in the semiconductor industry to make component parts. Materials cut to have a mirror-like surface yield the best performance, but the precision required is difficult to achieve at such a tiny scale.

Xinquan Zhang at A*STAR's Singapore Institute of Manufacturing Technology, along with co-workers at the same institute and the National University of Singapore, has developed a computer model that allows engineers to predict the best way of cutting different materials using vibration-assisted machining (VAM)1. This technique periodically interrupts the cutting process via the application of small-amplitude and high-frequency displacement to the cutting tool.

"Many researchers have observed that using VAM instead of conventional cutting techniques allows them to make cleaner, fracture-free cuts to most brittle materials," explains Zhang. "Because no theory or model exists to explain or predict this phenomenon, we decided to investigate."

At the nanoscale, brittle materials exhibit a certain degree of plasticity. Each material has a particular depth of cut that allows clean shearing to occur without chipping or fracturing on, or beneath, its surface. This point, known as the critical undeformed chip thickness, is directly correlated with material properties and machining conditions.

Zhang and his team studied the behavior of different brittle materials cut with VAM, during which two modes of cutting occur. In the ductile mode, plastic deformation caused by cutting is followed by elastic rebound and recovery of the material structure between vibrations. The brittle mode, on the other hand, removes material by uncontrolled crack propagation. Making a clean cut during ductile mode -- before the brittle mode dominates -- is therefore desirable.

The researchers modeled the energy consumption of each mode in terms of material removal as the vibrating tool moved, taking into account tool geometry, material properties and the cutting speed.

"By examining energy consumption and material deformation we were able to describe the mechanics when VAM moved from the ductile to the brittle mode," explains Zhang. "We then established a model to predict [the] critical undeformed chip thicknesses by finding the transition point between the two modes."

By examining energy consumption and material deformation we were able to describe the mechanics when VAM moved from the ductile to the brittle mode," explains Zhang. "We then established a model to predict [the] critical undeformed chip thicknesses by finding the transition point between the two modes."

Through a series of experiments, the team verified that the model accurately predicts the critical undeformed chip thicknesses of single-crystal silicon when cut at various VAM speeds.

"Our model will help engineers to select optimized machining parameters depending on their desired material," says Zhang. "Advantages could include higher productivity, lower costs, and improved product quality for semiconductor parts and other nanoscale technologies."

The A*STAR-affiliated researchers contributing to this research are from the Singapore Institute of Manufacturing Technology


Story Source:

The above story is based on materials provided by The Agency for Science, Technology and Research (A*STAR). Note: Materials may be edited for content and length.


Cite This Page:

The Agency for Science, Technology and Research (A*STAR). "The best cut for machining." ScienceDaily. ScienceDaily, 24 October 2013. <www.sciencedaily.com/releases/2013/10/131024114111.htm>.
The Agency for Science, Technology and Research (A*STAR). (2013, October 24). The best cut for machining. ScienceDaily. Retrieved October 21, 2014 from www.sciencedaily.com/releases/2013/10/131024114111.htm
The Agency for Science, Technology and Research (A*STAR). "The best cut for machining." ScienceDaily. www.sciencedaily.com/releases/2013/10/131024114111.htm (accessed October 21, 2014).

Share This



More Matter & Energy News

Tuesday, October 21, 2014

Featured Research

from universities, journals, and other organizations


Featured Videos

from AP, Reuters, AFP, and other news services

Graphene Paint Offers Rust-Free Future

Graphene Paint Offers Rust-Free Future

Reuters - Innovations Video Online (Oct. 21, 2014) British scientists have developed a prototype graphene paint that can make coatings which are resistant to liquids, gases, and chemicals. The team says the paint could have a variety of uses, from stopping ships rusting to keeping food fresher for longer. Jim Drury reports. Video provided by Reuters
Powered by NewsLook.com
Gulfstream G500, G600 Unveiling

Gulfstream G500, G600 Unveiling

Flying (Oct. 20, 2014) Watch Gulfstream's public launch of the G500 and G600 at their headquarters in Savannah, Ga., along with a surprise unveiling of the G500, which taxied up under its own power. Video provided by Flying
Powered by NewsLook.com
Japanese Scientists Unveil Floating 3D Projection

Japanese Scientists Unveil Floating 3D Projection

Reuters - Innovations Video Online (Oct. 20, 2014) Scientists in Tokyo have demonstrated what they say is the world's first 3D projection that floats in mid air. A laser that fires a pulse up to a thousand times a second superheats molecules in the air, creating a spark which can be guided to certain points in the air to shape what the human eye perceives as an image. Matthew Stock reports. Video provided by Reuters
Powered by NewsLook.com
Hey, Doc! Sewage, Beer and Food Scraps Can Power Chevrolet’s Bi-Fuel Impala

Hey, Doc! Sewage, Beer and Food Scraps Can Power Chevrolet’s Bi-Fuel Impala

3BL Media (Oct. 20, 2014) Hey, Doc! Sewage, Beer and Food Scraps Can Power Chevrolet’s Bi-fuel Impala Video provided by 3BL
Powered by NewsLook.com

Search ScienceDaily

Number of stories in archives: 140,361

Find with keyword(s):
Enter a keyword or phrase to search ScienceDaily for related topics and research stories.

Save/Print:
Share:

Breaking News:

Strange & Offbeat Stories


Space & Time

Matter & Energy

Computers & Math

In Other News

... from NewsDaily.com

Science News

Health News

Environment News

Technology News



Save/Print:
Share:

Free Subscriptions


Get the latest science news with ScienceDaily's free email newsletters, updated daily and weekly. Or view hourly updated newsfeeds in your RSS reader:

Get Social & Mobile


Keep up to date with the latest news from ScienceDaily via social networks and mobile apps:

Have Feedback?


Tell us what you think of ScienceDaily -- we welcome both positive and negative comments. Have any problems using the site? Questions?
Mobile: iPhone Android Web
Follow: Facebook Twitter Google+
Subscribe: RSS Feeds Email Newsletters
Latest Headlines Health & Medicine Mind & Brain Space & Time Matter & Energy Computers & Math Plants & Animals Earth & Climate Fossils & Ruins