Multi-axis NanoECM machine for sub-micro scale component manufacture

包括电子和医疗在内的许多行业都对小型化感兴趣，但这需要能够加工具有优越几何形状和表面拓扑结构的越来越小的部件。我们的传统电化学加工（ECM）机器销往全球客户，并在宏观尺度上运行，达到表面粗糙度~0.2微米Ra（取决于材料颗粒）。虽然高质量，但我们的客户表示，这种复杂性不利于亚微观尺度的加工，也无法提供现代工业所渴望的3D几何形状阵列。我们的新方法将解决这些缺点，并具有深远的工业和社会效益。PECM（与布鲁内尔大学和法拉第运动控制公司合作）希望设计一台4轴微脉冲电化学机器（micro-pECM），能够在单次加工迭代中进行亚微米尺度的多维加工；Ra降至5纳米。布鲁内尔大学已经通过两个fp7项目建立了一个实验室单轴原型，证明了这一概念。布鲁内尔大学现在希望在这一成功的基础上，与PECM-Systems和法拉第运动控制公司合作开发上述提议的试验机。好处：(1)客户可以开发新的、小型化的产品来推动销售；(2)具有成本效益的系统（相对便宜的技术，不需要专门的工具）；(3)降低材料消耗（环境效益）。关键技术风险与：(1)产生期望的电脉冲速率；(2)实时电极间自适应间隙监测、多轴控制和商用机器无法实现的材料去除率；(3)确保运动控制规范和运行模式与ECM硬件和电源系统相一致。

Many industries, including electronics and medical are interested in miniaturisation, but this requires the ability to machine increasingly small components with superior geometries and surface topologies. Our conventional electro-chemical machining (ECM) machines are sold to customers globally and operate at the macro-scale, attaining surface roughness ~0.2 micro-metre Ra (depending on material grain). Although high-quality, our customers state this intricacy is not conducive for machining at the sub-micro scale and does not deliver the array of 3D geometries modern industries aspire to. Our new approach will address these short-comings and have profound industrial and social benefits.PECM (in collaboration with Brunel University & Faraday Motion Control) wish to engineer a 4-axis micro-pulsed electro-chemical machine (micro-pECM) capable of fabricating sub-micro scale multi-dimensionally in a single machining iteration; with Ra down to 5-nano-metres.Brunel University have proven the concept by building a laboratory single-axis prototype through two FP7-projects. Brunel University now wish to build upon this success and partner with PECM-Systems and Faraday Motion Control to develop the above proposed test machine.BENEFITS: (1) customers can develop new, miniaturised products to drive sales; (2) cost effective system (relatively cheap technology and no specialist tooling required); (3) reduced material consumption (environmental benefit. .Key technical risks are associated with: (1) producing desired rate of electrical pulses; (2) Real-time inter electrode adaptive gap monitoring, control of multi-axis and material removal rates not achievable in a commercial machine; (3) ensuring motion control specification and operational mode is developed coherently to ECM hardware and power supply system.