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 Nov

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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