Low-cost micromachining development and application for engineering and technology education

Abstract

The goal of any undergraduate engineering or technical education program is to develop skill sets in students that allow them to be competitive in the job market; this is especially true for new emerging technologies. As companies find new modes to compete in the global market, they are always looking for a niche which will enable them to produce high quality products. Currently, there is a group of manufacturing companies in the Rockford, Illinois area that manufactures complex micro-machined parts with very tight tolerances and features. In order to move into this new micromachining area, the companies had to overcome two related issues. The first is how one can obtain low-cost, yet highly accurate micromachining equipment, and the second is finding skilled personnel to operate these new generation micro-machines. The purpose of this research was to develop a new generation of micro-machine which is financially accessible to these companies, develop a better understanding of this new paradigm in machining, and develop new student skills in this area. In the marketplace, there are many companies which produce and sell micromachining equipment. This equipment takes two forms; either very high end, very precise equipment which typically sells for over $100,000 or hobby machines which are not as precise, but sell for about $20,000. For a company to engage in micro-part manufacturing, they must have the capacity and capital to purchase equipment for producing complex, high quality parts. Not many companies have the ability to purchase top of the line micro-machining equipment. To remedy this problem, this researched focused on the development of a unique low-cost micro milling machine which allows for high precision and ease of use. This paper reports on the development process and testing of this low-cost machine. In addition, the paper presents machinability data that will enable companies to select optimum cutting condition, thus reducing costs associated with tool breakages. Detailed educational experiences which were developed utilizing micromachining techniques are also presented. This work also details the educational work which has been developed for the program students. © American Society for Engineering Education, 2009.