A hybrid process of raining co-deposition and rotary wire spark erosion in the development of a custom CBN tool for making a biochip injection mold

作者：Chen Shun Tong^*; Lai Yun Cheng

来源：Journal of Materials Processing Technology, 2014, 214(11): 2784-2795.

DOI：10.1016/j.jmatprotec.2014.06.016

• CBN wheel-tool array
• Raining co-deposition
• Rotary wire spark erosion
• One-off grinding

This study examines a hybrid process combining raining co-deposition and rotary wire spark erosion with one-off grinding to generate an array of microgrooves in the fabrication of biochip injection molds on NAK80 steel. A precision composite electroforming device that can create a rain like co-deposition effect to uniformly grow a Ni-based Cubic Boron Nitride (CBN) abrasive layer onto a wheel-blank substrate is proposed and employed. Slicing and dressing are conducted by using rotary wire spark erosion to make the co-deposited wheel-blank into a thin CBN wheel-tool with a grinding edge array that alternates between coarse and detailed. A multiple microgroove array on NAK80 steel is one-off generated by using the developed CBN wheel-tool array, swiftly creating a superior surface finish for biochip injection molding. A comprehensive examination of the quantitative and qualitative properties of the CBN wheel-tool was undertaken. Experimental results have been evaluated in terms of CBN grit content, accuracy of co-shaft machining, influence of grinding depth, shape of microgroove and tool wear as well as an estimation criterion for the CBN wheel-tool array.

• 出版日期2014-11