Extended Life Microtooling by Advanced Coating Technology (ELMACT)

Lead Research Organisation: University of Manchester
Department Name: Mechanical Aerospace and Civil Eng

Abstract

ELMACT will exploit its novel developments in nanostructured coatings & state-of-the-art laser processing to extend the life and facilitate the re-conditioning & re-use of hard-metal and other alloy micro-tooling, more specifically micro-mills and drills used in demanding machining applications, such as the machining of intricate patterns in hardened die steel moulds, the direct machining of micro-scale features in difficult- to-machine alloy components, composites, etc. The project will develop and pioneer the application of laser assisted sol-gel coating technology on micro-tools of micro- grain carbide substrates. ELMACT will benefit its industrial partners, which encompass the complete value chain, by improved tool performance, and by providing optimised machining conditions and reduced costs. It will reduce the partners' demand for materials, such as heavy metals, that are of increasing strategic importance. The University of Manchester will increase understanding of the use of coated micro-tools and develop specific IPR in the area of femto-second laser technology as applied to sol-gel coating technology, shot peening and re-shaping of micro-tools.

Publications

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Allcock A. (2010) The creation of knowledge in Machinery

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Allcock A. (2010) The creation of knowledge in Machinery

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Aramcharoen A (2009) Size effect and tool geometry in micromilling of tool steel in Precision Engineering

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Aramcharoen A (2008) Evaluation and selection of hard coatings for micro milling of hardened tool steel in International Journal of Machine Tools and Manufacture

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Imran M (2011) Assessment of machining performance using the wear map approach in micro-drilling in The International Journal of Advanced Manufacturing Technology

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Imran M (2015) Assessment of surface integrity of Ni superalloy after electrical-discharge, laser and mechanical micro-drilling processes in The International Journal of Advanced Manufacturing Technology

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Imran M (2008) An experimental investigation of deep-hole microdrilling capability for a nickel-based superalloy in Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

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Jaffery S (2015) Statistical analysis of process parameters in micromachining of Ti-6Al-4V alloy in Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

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Marimuthu S (2010) Laser removal of TiN coatings from WC micro-tools and in-process monitoring in Optics & Laser Technology

 
Description A new technique to enable production of small holes less than 1 mm in diameter in difficult to cut aerospace alloys.

A method for cleaning cutting tools and materials by using lasers to remove coatings and enable the tooling to be re-used or recoated.

A new method combining laser processing followed by micro drilling, in producing small holes. Method extends life of drill and enables faster drilling.
Exploitation Route Companies can exploit the results. Other researchers can use the techniques for other materials.
Sectors Aerospace, Defence and Marine,Education,Manufacturing, including Industrial Biotechology

 
Description The findings supported the collaborating companies in developing micro machining capability. Laser cleaning of cutting tools was extended to laser cleaning for aerospace application in the SAMULET project
First Year Of Impact 2010
Sector Aerospace, Defence and Marine,Manufacturing, including Industrial Biotechology
Impact Types Economic

 
Description Micro milling process development for NGV
Amount £38,000 (GBP)
Organisation Rolls Royce Group Plc 
Sector Private
Country United Kingdom
Start 01/2009 
End 12/2009
 
Description Agie Charmilles Ltd 
Organisation Agie Charmilles
Country United Kingdom 
Sector Private 
Start Year 2007
 
Description Micro Systems (UK) Limited 
Organisation Micro Systems (UK) Limited
Country United Kingdom 
Sector Private 
Start Year 2007
 
Description Rainford Precision Machines 
Organisation Rainford Precision Machines
Country United Kingdom 
Sector Private 
Start Year 2007
 
Description Rolls-Royce plc 
Organisation Rolls Royce Group Plc
Country United Kingdom 
Sector Private 
Start Year 2007
 
Description Teer Coatings Ltd 
Organisation Teer Coatings Ltd
Country United Kingdom 
Sector Private 
Start Year 2007
 
Description WLR Prototype Engineers Limited 
Organisation WLR Prototype Engineers Limited
Country United Kingdom 
Sector Private 
Start Year 2007