A hybrid process of raining co-deposition and rotary wire spark erosion in the development of a custom CBN tool for making a biochip injection mold

Shun-Tong Chen, Yun Cheng Lai

Research output: Contribution to journalArticle

1 Citation (Scopus)

Abstract

This study examines a hybrid process combining raining co-deposition and rotary wire spark erosion with one-off grinding to generate an array of microgrooves in the fabrication of biochip injection molds on NAK80 steel. A precision composite electroforming device that can create a rain like co-deposition effect to uniformly grow a Ni-based Cubic Boron Nitride (CBN) abrasive layer onto a wheel-blank substrate is proposed and employed. Slicing and dressing are conducted by using rotary wire spark erosion to make the co-deposited wheel-blank into a thin CBN wheel-tool with a grinding edge array that alternates between coarse and detailed. A multiple microgroove array on NAK80 steel is one-off generated by using the developed CBN wheel-tool array, swiftly creating a superior surface finish for biochip injection molding. A comprehensive examination of the quantitative and qualitative properties of the CBN wheel-tool was undertaken. Experimental results have been evaluated in terms of CBN grit content, accuracy of co-shaft machining, influence of grinding depth, shape of microgroove and tool wear as well as an estimation criterion for the CBN wheel-tool array.

Original languageEnglish
Pages (from-to)2784-2795
Number of pages12
JournalJournal of Materials Processing Technology
Volume214
Issue number11
DOIs
Publication statusPublished - 2014 Jan 1

Fingerprint

Biochips
Cubic boron nitride
Nitrides
Erosion
Electric sparks
Wheel
Injection
Wheels
Wire
Grinding
Steel
Electroforming
Tool Wear
Injection Molding
Slicing
Qualitative Properties
Molds
Abrasives
Injection molding
Machining

Keywords

  • CBN wheel-tool array
  • One-off grinding
  • Raining co-deposition
  • Rotary wire spark erosion

ASJC Scopus subject areas

  • Ceramics and Composites
  • Computer Science Applications
  • Metals and Alloys
  • Industrial and Manufacturing Engineering

Cite this

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abstract = "This study examines a hybrid process combining raining co-deposition and rotary wire spark erosion with one-off grinding to generate an array of microgrooves in the fabrication of biochip injection molds on NAK80 steel. A precision composite electroforming device that can create a rain like co-deposition effect to uniformly grow a Ni-based Cubic Boron Nitride (CBN) abrasive layer onto a wheel-blank substrate is proposed and employed. Slicing and dressing are conducted by using rotary wire spark erosion to make the co-deposited wheel-blank into a thin CBN wheel-tool with a grinding edge array that alternates between coarse and detailed. A multiple microgroove array on NAK80 steel is one-off generated by using the developed CBN wheel-tool array, swiftly creating a superior surface finish for biochip injection molding. A comprehensive examination of the quantitative and qualitative properties of the CBN wheel-tool was undertaken. Experimental results have been evaluated in terms of CBN grit content, accuracy of co-shaft machining, influence of grinding depth, shape of microgroove and tool wear as well as an estimation criterion for the CBN wheel-tool array.",
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