European initiative: MICROMAN –European Training Network ...

European initiative: MICROMAN – European Training Network on Process Fingerprint for Zero‐defect Net‐shape Micromanufacturing

G. Tosello (*)(2), G. Bissacco (2), H.N. Hansen (1), N. Bay (1), M. Calaon (RA)Department of Mechanical Engineering, Technical University of Denmark(*) presenting author ([email protected])

M. Arentoft (2)IPU Innovation Factory, Process Technology

The International Academy for Production Engineering (CIRP)65th General Assembly (Cape Town, South Africa)

August 28th 2015, STC ‘P’

28/08/20152 CIRP GA 2015, G. Tosello, Technical University of Denmark

• Ubiquitous connectivity

Global trends – Society


• Ubiquitous connectivity

Global trends – Society


• Hearing ability, communication, well‐being

Global trends – Ageing population


• High precision micro manufacturing• Mass fabrication • Quality assurance• Skills & expertise

Global trends – Miniaturization


Project Identity CardEU H2020 MARIE SKŁODOWSKA‐CURIE ACTIONEuropean Innovative Training Network

Starting date: 01/10/2015

Duration: 48 months


• Micro manufacturing processes development• Process/product finger print establishment and validation• Process/product monitoring and quality assurance

Project objectives

Research methodologyMulti‐disciplinary research approachResearch based training of 13 Early Stage Researchers70%‐20%‐10% approach


Research methodology

ESR No.

Core Micro Manufacturing

Technology

Complementary Micro Manuf.

Technology(ies)

Key-enabling Technologies

Main Supervisor

Partner

Industrial/ Research Partner(s)

Key-industrial application

70% 20% 10%

1. µ-Injection Moulding µ-Milling, µ-EDM Process monitoring Micro metrology DTU ORTOFON Non-invasive brain

surgery

2. µ-Mechanical Polishining

µ-Forming, µ-EDM

Process monitoring Micro metrology DTU STRECON Machine tool, µ-die

industry

3. µ-EDM µ-Milling Process monitoring Micro metrology KUL SARIX Machine tool, µ-

tool industry

4. µ-ECM milling µ-EDM Process monitoring Micro metrology KUL SARIX Machine tool, µ-

tool industry

5. µ-ECM milling µ-Jet ECM Process monitoring Micro metrology TUC ECM

TECHNOLOGIES µ-tool industry, surgical instr.

6. µ-Plasma Polishing µ-Forming Process monitoring Micro metrology TUC BTE, ECM

TECHNOLOGIES Machine tool, surgical instr.

7. µ-Grinding µ-Milling, µ-Polishing

Process monitoring Micro metrology UBREM SIOS Dental impl.,

metrology

8. µ-Injection Moulding µ-Milling, µ-Polishing

Process monitoring Micro metrology UBREM DESMA,

POLYOPTICS Machine tool, surgical instr.

9. µ-Forming µ-Milling Process monitoring Micro metrology USTRAT PASCOE ENG. LTD Surgical

instruments

10. µ-Extrusion µ-Milling, µ-Polishing

Process monitoring Micro metrology POLIMI ENKI, MARPOSS Medical tech.,

metrology

11. Integrated Micro Manuf. Metrology µ-Injection Moulding Process monitoring

Micro metrology UNOTT ALICONA Metrology instrumentation

12. µ-Forming µ-EDM Process monitoring Micro metrology IPU DTU, STRAT Machine tool,

dental implants

13. µ-Injection Moulding µ-Grinding Process monitoring Micro metrology UBRAD MICROSYSTEMS,

ULTRASION µ-drug delivery,

machine tool


Project work plan


9 Beneficiaries 14 Industrial Partners


Project consortium

TECHNICAL UNIVERSITY OF DENMARKIPU, INNOVATIO FACTORYORTOFONSTRECON

UNIVERSITY OF BREMENCHEMNITZ UNIVERSITY OF TECHNOLOGYBECKMANN‐INSTITUT FÜR TECHNOLOGIEENTWICKLUNG E.VSIOSDESMAPOLYOPTICS

POLYTECHNIC UNIVERSITY OF MILANENKIMARPOSS

ULTRASION

UNIVERSITY OF STRATHCLYDEUNIVERSITY BRADFORDUNIVERSITY OF NOTTINGHAMMICROSYSTEMS UKPASCOE ENGINEERING LTD

UNIVERSITY OF LEUVEN

SARIX

ALICONA

ECM TECHNOLOGIES


• (1) Product Manufacturing Fingerprint• (2) Process Manufacturing Fingerprint• (3) Integrated Product and Process Manufacturing Fingerprint• MICROMAN aims at reducing the off‐line metrology effort by at least 40‐50% ensuring at same time zero‐defect micro manufacturing processes

Approach – Fingerprint / Zero‐defect / Net‐shape


Machine data

Sensor data

Product characteristics

-OFF-LINE/IN-LINE

Approach – Fingerprint / Zero‐defect / Net‐shape


50

52

54

56

58

60

62

64

66

68

70

Sample1

Sample2

Sample3

Sample4

Sample5

Sample6

Sample7

Sample8

Sample9

Crosses c

hann

els d

epth [n

m]

Silicon Wafer Nickel Shim Polymer Samples

Product/Process monitoring Dimensions & Injectionpressure (based on machine measurements)

0

100

200

300

400

500

600

700

800

0 50 100 150 200 250

Injection pressure [b

ar]

Injection time [ms]

Test 1

Test 2

Test 3

Test 4

Test 5

Test 6

Test 7

Test 8

Test 9

Test 10

Machine data

Product characteristics

[Calaon, Tosello, et al. (2015) Microsys. Technol., DOI10.1007/s00542‐013‐2025‐3]


PiPc

Precision injection molding and monitoring

Machine data and sensor data correlation

Machine data

Sensor data

[Griffiths, Tosello et al. (2011), Trans. Of ASME, doi:10.1115/1.4003953]


Injection and cavity pressure monitoring

0 1000 2000 3000 4000 5000 6000

0

5

10

15

20

25

Time [ms]

Pre

ssur

e [M

Pa]

PInjectionPCavity

Start of injection

Polymer melt frontreaches cavity sensor

Maximum injection pressure

End of injection cycle

Start of demoulding cycle

Mould opening

Sealing point

Machine data

Sensor data


Correlation between cavity pressure and injection pressure

Mea

n of

Pm

ax (

inje

ctio

n)

800200

21,6

21,2

20,8

20,4

20,0

OnOff

13070

21,6

21,2

20,8

20,4

20,0

300240

Vi [mm/s] Ph

Tm [°C] Tb [°C]

Main Effects Plot (data means) for Pmax (injection)

Mea

n of

Pm

ax (

cavi

ty)

800200

18

17

16

15

14OnOff

13070

18

17

16

15

14300240

Vi [mm/s] Ph

Tm [°C] Tb [°C]

Main Effects Plot (data means) for Pmax (cavity)Machine data

Sensor data

[Griffiths, Tosello et al. (2011) Trans. Of ASME

doi:10.1115/1.4003953]


Integrated in‐line metrology and micro manufacturing

http://www.fp7‐cotech.eu/179/


MICROMAN Micro Manufacturing Workshops Programmehttp://www.microman.mek.dtu.dk/Workshops

• Workshop 1 – Micro Manufacturing PhD Summer School / DTU• Workshop 2 – Micro/Nano Metrology PhD Summer School / Univ. of Nottingham• Workshop 3 – Micro Moulding Workshop / University of Bradford (UK)• Workshop 4 – Micro Tooling and Grinding Workshop / Univ. of Bremen• Workshop 5 – Micro Electrical Discharge Machining Workshop / KU Leuven• Workshop 6 – Micro lectrochemical Machining (μECM) / TU Chemnitz• Workshop 7 – Micro Forming Workshop / University of Strathclyde (UK)• Workshop 8 – μ‐Milling and μ‐Extrusion Workshops / Politecnico di Milano


MICROMAN highlights

• Micro manufacturing process fingerprint, zero‐defect net‐shape µ‐manufacturing

• Multi‐disciplinary training• Industrial validation of µ‐manufacturing processes• Industrial applications bio‐medical, health‐care, machine tool, pharmaceutical, quality control and metrology sectors

• Integrated PROCESS/PRODUCT monitoring and quality assurance

28/08/201521 CIRP GA 2015, G. Tosello, Technical University of DenmarkRecruiting takes place during January – February 2016

ESRs PhD projects start: 01/04/2016


Thank you for your attention

http://www.microman.mek.dtu.dk/

European initiative: MICROMAN – European Training Network on Process Fingerprint for Zero‐defect Net‐shape Micromanufacturing

G. Tosello (*)(2), G. Bissacco (2), H.N. Hansen (1), N. Bay (1), M. Calaon (RA)Department of Mechanical Engineering, Technical University of Denmark(*) presenting author ([email protected])

M. Arentoft (2)IPU Innovation Factory, Process Technology

The International Academy for Production Engineering (CIRP)65th General Assembly (Cape Town, South Africa)

August 28th 2015, STC ‘P’

http://www.microman.mek.dtu.dk

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