Microengineering of Metals and Ceramics: Part I: Design, Tooling, and Injection Molding - Hardcover

Hardcover

ISBN 10: 3527312080 ISBN 13: 9783527312085

Verlag: Wiley-VCH, 2005

Inhaltsangabe

Microstructures, electronics, nanotechnology - these vast fields of research are growing together as the size gap narrows and many different materials are combined. Current research, engineering sucesses and newly commercialized products hint at the immense innovative potentials and future applications that open up once mankind controls shape and function from the atomic level right up to the visible world without any gaps.
 
In this volume, authors from three major competence centres for microengineering illustrate step by step the process from designing and simulating microcomponents of metallic and ceramic materials to replicating micro-scale components by injection molding.

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Über die Autorin bzw. den Autor

Prof. Dr.-Ing. Detlef Löhe studied mechanical engineering at the Technical University of Karlsruhe, Germany and obtained his Ph.D. in 1980. After heading the microstructure and mechancal behaviour working group there, he was appointed in 1991 as professor for materials science at Paderborn University, Germany, where he received an award for outstanding teaching achievements in 1994. In the same year, he returned to the Institute for Materials Science and Enginering I at Karlsruhe Technical University as its Director. He is Speaker of the Collaborative Research Centre 499 "Design, production and quality assurance of molded microparts constructed of metals and ceramics" and has been a Senator of the Deutsche Forschungsgemeinschaft (DFG) since 2003.
His research interests focus on metallic and ceramic materials properties and durability under different kinds of stress, component manufacture and behaviour, optimisation of heat treatment methods, and failure analysis.
 
Prof. Dr.-Ing. Jürgen Haußelt studied Physics and Materials Sciences at the University of Erlangen, Germany. After his doctorate and a research stay at Stanford University he joined Degussa AG in 1977, starting in metals research. After having worked as technical director in Degussa´s subsidiary in New York City, he returned to Germany in 1985 and was first in charge of metals research, then managed the entire materials development und process technology of Degussa´s corporate division "Metals". In 1993 he joined Forschungszentrum Karlsruhe as head of the Institute of Materials Research III. In addition, he was appointed professor at Freiburg University as Chair for Micromaterials Process Technology at IMTEK in 1996. In 1998 he became member of the supervisory board of Norddeutsche Affinerie AG, Hamburg.

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The gateway to the micro and nano worlds: AMN provides cutting-edge reviews and detailed case studies by top authors from science and industry, covering technologies, devices and advanced systems. Together, these have an immense innovative application potential that opens up with control of shape and function from the atomic level right up to the visible world without any technological gaps.<br> <br> This and the following volume cover all angles of micro-scale parts and components engineering from both metallic and ceramic materials, a very promising field which is a strong source of innovation and development for micro process technology, aerospace applications, sensors, actors, medical and dental as well as many other applications.<br> <br> In this volume, readers are introduced to this field and led from the design and modeling aspects to tooling, molds, and micro injection molding as a powerful replication technology.<br> <br> From the Contents:<br> Design Environment and Design Flow<br> Modelling in Design<br> Modelling in Micro-PIM<br> Strategies for Manufacture of Mold Inserts<br> Micro End Milling in Hardened Steel<br> 3D Microstructuring of Mold Inserts by Laser Removal<br> Micro-EDM of Mold Inserts<br> Lithographic Fabrication of Mold Inserts<br> Material States, Surface Conditioning<br> Micro Injection Molding: Principles and Challenges<br> Micro-MIM<br> Micro-CIM<br> <br> Part II covers casting and forming techniques, automation, quality assurance, and component properties.

Aus dem Klappentext

The gateway to the micro and nano worlds: AMN provides cutting-edge reviews and detailed case studies by top authors from science and industry, covering technologies, devices and advanced systems. Together, these have an immense innovative application potential that opens up with control of shape and function from the atomic level right up to the visible world without any technological gaps.
 
This and the following volume cover all angles of micro-scale parts and components engineering from both metallic and ceramic materials, a very promising field which is a strong source of innovation and development for micro process technology, aerospace applications, sensors, actors, medical and dental as well as many other applications.
 
In this volume, readers are introduced to this field and led from the design and modeling aspects to tooling, molds, and micro injection molding as a powerful replication technology.
 
From the Contents:
Design Environment and Design Flow
Modelling in Design
Modelling in Micro-PIM
Strategies for Manufacture of Mold Inserts
Micro End Milling in Hardened Steel
3D Microstructuring of Mold Inserts by Laser Removal
Micro-EDM of Mold Inserts
Lithographic Fabrication of Mold Inserts
Material States, Surface Conditioning
Micro Injection Molding: Principles and Challenges
Micro-MIM
Micro-CIM
 
Part II covers casting and forming techniques, automation, quality assurance, and component properties.

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Microengineering of Metals and Ceramics

Part I: Design, Tooling, and Injection Molding

John Wiley & Sons

Copyright © 2005 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
All right reserved.
ISBN: 978-3-527-31208-5

Chapter One

Design Environment and Design Flow

A. Albers, J. Marz, Institute of Product Development (IPEK), University of Karlsruhe (TH), Germany

Abstract

The design flow for primary-shaped microcomponents and microsystems is presented. As a characteristic of microspecific design, the approach is predominantly driven by technology. To integrate the relevant technological demands and restrictions into the design synthesis for a realizable embodiment design in accordance with the specified function, design rules are defined. These represent mandatory instructions for the designer. To support the designer effectively the design rules are provided within a computer-aided design environment. In addition to an information portal, an embodiment design unit is built up on the basis of the 3D CAD system Unigraphics, which includes an application for knowledge-based engineering (KBE). The rule-based design methodology was used for the development and design of a microplanetary gear.

Keywords

design environment; design flow; target system definition; operation system; object system; design rule; knowledge-based engineering; methodological aid

1.1 Introduction 4 1.1.1 State-of-the-Art of Design Flows and Design Environments within Microtechnology 4 1.1.2 Mechanical Microproduction 5 1.2 Design Flow 6 1.2.1 Specific Issues Within the Design of Microsystems 6 1.2.1.1 Dominance of Technologies 6 1.2.1.2 Surface-to-Volume Ratio 6 1.2.1.3 Dynamics 7 1.2.1.4 Standardization 7 1.2.1.5 Validation 7 1.2.1.6 Enhanced Material Spectrum 7 1.2.1.7 Emphasis on Actuators 7 1.2.2 Microspecific Design Flow 7 1.3 Design Rules 9 1.3.1 Basics 9 1.3.1.1 Definition 9 1.3.1.2 Derivation of Design Rules 10 1.3.2 Design Rules Derived from Restrictions of Production Technology 11 1.3.2.1 Design Rules for Mold Insert Manufacturing 13 1.3.2.2 Design Rules for Replication Techniques 14 1.4 Design Environment 18 1.4.1 Information Unit 20 1.4.2 Embodiment Design Unit 20 1.4.2.1 Preparing Elementary Rules for Computer-aided Design Rule Check 21 1.4.2.2 Design Rule Check 24 1.5 Conclusion 27 1.6 References 27

1.1 Introduction

Microtechnology involves technologies for manufacturing and assembling predominantly micromechanical, microelectrical, microfluidic and microoptical components and systems with characteristic structures with the dimension of microns. In doing so, microproduction technologies take on a key role, since their process-specific parameters and boundary conditions determine the smallness and attainable quality features of the components. Owing to the ongoing progress in microtechnology and the increasing penetration of the market with medium-sized and large-batch products, development steps preliminary and subsequent to production are becoming more and more relevant for an effective design in compliance with the requirements. Therefore, the designer needs to be supported by a technological basic knowledge and know-how, regardless of individual persons.

1.1.1 State-of-the-Art of Design Flows and Design Environments within Microtechnology

Microtechnologies include silicon microsystem technology, the LIGA process and mechanical microproduction technology.

Silicon microsystem technology is the most widespread microtechnology throughout the world. It is based on the process technology of integrated circuits (ICs) and benefits from a comprehensive know-how from microelectronics. Unlike in microelectronics, microtechnological products integrate active and passive functional elements, which rely on at least two elementarily different physical, chemical or biochemical effects and working principles. In addition to sensors and information processing, particularly actuator functions are performed. The predominantly 2.5-dimensional and sometimes three-dimensional structures use silicon as substrate with its excellent mechanical properties. Along with others, all these characteristics of silicon micromechanical systems have required a specific design methodology ever since a critical level of development from research into industry was reached. Different design process models are known, which among other things integrate analytical and numerical simulation tools. Silicon-based micromechanical products are developed in an iterative sequence of synthesis and analysis steps. A specific difficulty lies in the deviation between the designed target structure and the actual structure after the optical lithography and etching process. Therefore, compensation structures are introduced into the design and simulation environment, adjusting the determined structure by dimensional add-on and auxiliary structures. Design rules are introduced as a methodological aid to represent this technological information. Design rules have been used in microelectronics since the early 1980s to enable very large-scale integrated (VLSI) circuits to be synthesized automatically to the extent of nearly 100%. Silicon microsystem technology has now reached a high degree of development status. A lot of research programs have led to design flow descriptions and collections of design rules.

Like silicon microsystem technology, the LIGA process utilizes mask-based process steps. The LIGA process approaches an obviously broader range of materials and is characterized by extremely high aspect ratios with at the same time the smallest lateral structure dimensions. LIGA permits the manufacture of mold inserts which can be used in replication techniques for large-batch parts (Chapter 8). In addition to thermoplastics, also metallic and ceramic materials are processed. To support the design and process, engineering design rules are utilized which give - depending on the process sequence - instructions for a design for manufacturing and for separating, manipulating and assembling components. Within different research programs, design environments for computer-aided design of LIGA microstructures embedding design rules were developed. The computer-aided design of LIGA microstructures still shows a high demand. A standardized model for methodological design flow in the LIGA process is lacking to date.

1.1.2 Mechanical Microproduction

To come up with a more cost-effective, medium-sized and large-batch suitable process for manufacturing microsystems, the potential of miniaturizing mechanical production technologies has been increasingly investigated in recent years. Predominantly staged production process sequences for manufacturing mold inserts by wear-resistant materials followed by a replication step show outstanding future prospects. Technologies such as micromilling and laser machining are suitable for manufacturing complex three-dimensional free-form surfaces (Chapters 5-7). By replication techniques such as micropowder injection molding, high-strength microcomponents and microsystems from metallic and ceramic materials can be produced in large quantities (Chapters 11 and 12).

When designing...

Details zur Ausgabe

• Verlag: Wiley-VCH
• Erscheinungsdatum: 2005
• Sprache: Englisch
• ISBN 10: 3527312080
• ISBN 13: 9783527312085
• Einband: Gebundene Ausgabe
• Auflage: 1
• Anzahl der Seiten: 392
• Herausgeber: Löhe Detlef, Haußelt Jürgen
• Kontakt zum Hersteller: Wiley-VCH GmbH; product_safety@wiley.com; ; Boschstrasse 12; Weinheim; 69469; Deutschland