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.
Organisations
Publications
Okasha M
(2010)
Sequential laser and mechanical micro-drilling of Ni superalloy for aerospace application
in CIRP Annals
Aramcharoen A
(2008)
Evaluation and selection of hard coatings for micro milling of hardened tool steel
in International Journal of Machine Tools and Manufacture
Mian A
(2011)
Identification of factors that dominate size effect in micro-machining
in International Journal of Machine Tools and Manufacture
S Mativenga
(2010)
Establishing a basis for sustainable re-use of cutting tools through laser decoating
in Journal of Machine Engineering
Okasha M
(2011)
Sequential Laser Mechanical Microdrilling of Inconel 718 Alloy
in Journal of Manufacturing Science and Engineering
Allcock A.
(2010)
The creation of knowledge
in Machinery
Marimuthu S
(2010)
Laser removal of TiN coatings from WC micro-tools and in-process monitoring
in Optics & Laser Technology
Aramcharoen A
(2009)
Size effect and tool geometry in micromilling of tool steel
in Precision Engineering
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
Marimuthu S
(2011)
Laser stripping of TiAlN coating to facilitate reuse of cutting tools
in Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
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 |