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European initiative: MICROMAN – European Training Network on Process Fingerprint for Zero‐defect Net‐shape Micromanufacturing
G. Tosello (*)(2), G. Bissacco (2), H.N. Hansen (1), N. Bay (1), M. Calaon (RA)Department of Mechanical Engineering, Technical University of Denmark(*) presenting author ([email protected])
M. Arentoft (2)IPU Innovation Factory, Process Technology
The International Academy for Production Engineering (CIRP)65th General Assembly (Cape Town, South Africa)
August 28th 2015, STC ‘P’
28/08/20152 CIRP GA 2015, G. Tosello, Technical University of Denmark
• Ubiquitous connectivity
Global trends – Society
28/08/20153 CIRP GA 2015, G. Tosello, Technical University of Denmark
• Ubiquitous connectivity
Global trends – Society
28/08/20154 CIRP GA 2015, G. Tosello, Technical University of Denmark
• Hearing ability, communication, well‐being
Global trends – Ageing population
28/08/20155 CIRP GA 2015, G. Tosello, Technical University of Denmark
• High precision micro manufacturing• Mass fabrication • Quality assurance• Skills & expertise
Global trends – Miniaturization
28/08/20156 CIRP GA 2015, G. Tosello, Technical University of Denmark
Project Identity CardEU H2020 MARIE SKŁODOWSKA‐CURIE ACTIONEuropean Innovative Training Network
Starting date: 01/10/2015
Duration: 48 months
28/08/20157 CIRP GA 2015, G. Tosello, Technical University of Denmark
• Micro manufacturing processes development• Process/product finger print establishment and validation• Process/product monitoring and quality assurance
Project objectives
Research methodologyMulti‐disciplinary research approachResearch based training of 13 Early Stage Researchers70%‐20%‐10% approach
28/08/20158 CIRP GA 2015, G. Tosello, Technical University of Denmark
13. µ-Injection Moulding µ-Grinding Process monitoring Micro metrology UBRAD MICROSYSTEMS,
ULTRASION µ-drug delivery,
machine tool
28/08/20159 CIRP GA 2015, G. Tosello, Technical University of Denmark
Project work plan
28/08/201510 CIRP GA 2015, G. Tosello, Technical University of Denmark
9 Beneficiaries 14 Industrial Partners
28/08/201511 CIRP GA 2015, G. Tosello, Technical University of Denmark
Project consortium
TECHNICAL UNIVERSITY OF DENMARKIPU, INNOVATIO FACTORYORTOFONSTRECON
UNIVERSITY OF BREMENCHEMNITZ UNIVERSITY OF TECHNOLOGYBECKMANN‐INSTITUT FÜR TECHNOLOGIEENTWICKLUNG E.VSIOSDESMAPOLYOPTICS
POLYTECHNIC UNIVERSITY OF MILANENKIMARPOSS
ULTRASION
UNIVERSITY OF STRATHCLYDEUNIVERSITY BRADFORDUNIVERSITY OF NOTTINGHAMMICROSYSTEMS UKPASCOE ENGINEERING LTD
UNIVERSITY OF LEUVEN
SARIX
ALICONA
ECM TECHNOLOGIES
28/08/201512 CIRP GA 2015, G. Tosello, Technical University of Denmark
• (1) Product Manufacturing Fingerprint• (2) Process Manufacturing Fingerprint• (3) Integrated Product and Process Manufacturing Fingerprint• MICROMAN aims at reducing the off‐line metrology effort by at least 40‐50% ensuring at same time zero‐defect micro manufacturing processes
Approach – Fingerprint / Zero‐defect / Net‐shape
28/08/201513 CIRP GA 2015, G. Tosello, Technical University of Denmark
Machine data
Sensor data
Product characteristics
-OFF-LINE/IN-LINE
Approach – Fingerprint / Zero‐defect / Net‐shape
28/08/201514 CIRP GA 2015, G. Tosello, Technical University of Denmark
50
52
54
56
58
60
62
64
66
68
70
Sample1
Sample2
Sample3
Sample4
Sample5
Sample6
Sample7
Sample8
Sample9
Crosses c
hann
els d
epth [n
m]
Silicon Wafer Nickel Shim Polymer Samples
Product/Process monitoring Dimensions & Injectionpressure (based on machine measurements)
0
100
200
300
400
500
600
700
800
0 50 100 150 200 250
Injection pressure [b
ar]
Injection time [ms]
Test 1
Test 2
Test 3
Test 4
Test 5
Test 6
Test 7
Test 8
Test 9
Test 10
Machine data
Product characteristics
[Calaon, Tosello, et al. (2015) Microsys. Technol., DOI10.1007/s00542‐013‐2025‐3]
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PiPc
Precision injection molding and monitoring
Machine data and sensor data correlation
Machine data
Sensor data
[Griffiths, Tosello et al. (2011), Trans. Of ASME, doi:10.1115/1.4003953]
28/08/201516 CIRP GA 2015, G. Tosello, Technical University of Denmark
Injection and cavity pressure monitoring
0 1000 2000 3000 4000 5000 6000
0
5
10
15
20
25
Time [ms]
Pre
ssur
e [M
Pa]
PInjectionPCavity
Start of injection
Polymer melt frontreaches cavity sensor
Maximum injection pressure
End of injection cycle
Start of demoulding cycle
Mould opening
Sealing point
Machine data
Sensor data
28/08/201517 CIRP GA 2015, G. Tosello, Technical University of Denmark
Correlation between cavity pressure and injection pressure
Mea
n of
Pm
ax (
inje
ctio
n)
800200
21,6
21,2
20,8
20,4
20,0
OnOff
13070
21,6
21,2
20,8
20,4
20,0
300240
Vi [mm/s] Ph
Tm [°C] Tb [°C]
Main Effects Plot (data means) for Pmax (injection)
Mea
n of
Pm
ax (
cavi
ty)
800200
18
17
16
15
14OnOff
13070
18
17
16
15
14300240
Vi [mm/s] Ph
Tm [°C] Tb [°C]
Main Effects Plot (data means) for Pmax (cavity)Machine data
Sensor data
[Griffiths, Tosello et al. (2011) Trans. Of ASME
doi:10.1115/1.4003953]
28/08/201518 CIRP GA 2015, G. Tosello, Technical University of Denmark
Integrated in‐line metrology and micro manufacturing
http://www.fp7‐cotech.eu/179/
28/08/201519 CIRP GA 2015, G. Tosello, Technical University of Denmark
• Workshop 1 – Micro Manufacturing PhD Summer School / DTU• Workshop 2 – Micro/Nano Metrology PhD Summer School / Univ. of Nottingham• Workshop 3 – Micro Moulding Workshop / University of Bradford (UK)• Workshop 4 – Micro Tooling and Grinding Workshop / Univ. of Bremen• Workshop 5 – Micro Electrical Discharge Machining Workshop / KU Leuven• Workshop 6 – Micro lectrochemical Machining (μECM) / TU Chemnitz• Workshop 7 – Micro Forming Workshop / University of Strathclyde (UK)• Workshop 8 – μ‐Milling and μ‐Extrusion Workshops / Politecnico di Milano
28/08/201520 CIRP GA 2015, G. Tosello, Technical University of Denmark
MICROMAN highlights
• Micro manufacturing process fingerprint, zero‐defect net‐shape µ‐manufacturing
• Multi‐disciplinary training• Industrial validation of µ‐manufacturing processes• Industrial applications bio‐medical, health‐care, machine tool, pharmaceutical, quality control and metrology sectors
• Integrated PROCESS/PRODUCT monitoring and quality assurance
28/08/201521 CIRP GA 2015, G. Tosello, Technical University of DenmarkRecruiting takes place during January – February 2016
ESRs PhD projects start: 01/04/2016
28/08/201522 CIRP GA 2015, G. Tosello, Technical University of Denmark
Thank you for your attention
http://www.microman.mek.dtu.dk/
European initiative: MICROMAN – European Training Network on Process Fingerprint for Zero‐defect Net‐shape Micromanufacturing
G. Tosello (*)(2), G. Bissacco (2), H.N. Hansen (1), N. Bay (1), M. Calaon (RA)Department of Mechanical Engineering, Technical University of Denmark(*) presenting author ([email protected])
M. Arentoft (2)IPU Innovation Factory, Process Technology
The International Academy for Production Engineering (CIRP)65th General Assembly (Cape Town, South Africa)