Laboratories

Ultra-precision machining is an advanced, cutting-edge manufacturing process that produces intricate and high-quality components with exceptionally tight tolerances and surface quality, often at the sub-micron or nanometric level. 

The Ultra-Precision Manufacturing Cell (UPMC) hosts a state-of-the-art Dimond Turn Machine (DTM) established in the Mechanical Engineering Department with the support of the Institute of Eminence (IoE). The facility is supported by air-bearing spindles, pneumatic slides, high rigidity, high precision tools, and feedback control to achieve nanoscale surface roughness. This machine uses a single crystal (natural or synthetic) diamond-tipped tool to manufacture high-quality precision components, like molds, lenses, mirrors/reflectors, diffractive, cavities from metals, semiconductors, acrylic, and other materials. 

The components produced by diamond turning are used in optical assemblies in telescopes, video projectors, missile guidance systems, lasers, scientific research instruments, and numerous other systems and devices. Unlike other conventionally machined surfaces, diamond-turned surfaces have a high specular brightness and require no additional polishing or buffing.

Electrochemical machining (ECM) stands out as a non-conventional process where material removal occurs by dissolving metal atoms from the anode within an electrolytic cell. Its subset, electrochemical micromachining (ECMM), specializes in the precise fabrication of micro features, typically less than 1000 µm. An advantageous aspect of ECMM compared to conventional machining methods lies in its ability to process any electrically conductive material, regardless of hardness. Notably, ECMM does not induce changes in material properties through mechanical or thermal energy, making it particularly suitable for working with superior materials and shape memory alloys. The ECMM process encompasses various operations such as cutting, drilling, polishing, slotting, and die manufacturing.

Our research team has developed an indigenous EcMM facility boasting capabilities such as a feed movement of 0.3 µm/s with a current sensing feedback controller and real-time monitoring system. This facility is equipped to perform all aforementioned operations. Furthermore, our team is actively exploring new avenues in micro-slotting, micro tool fabrication (straight and tapered), and surface polishing using wire-ECM processes. Some of our research outcomes are showcased herein.

We house a cutting-edge electrochemical anodization setup meticulously constructed in-house. This setup serves as a cornerstone in our research endeavours, enabling the synthesis of titanium nanotubes (TNT) on various titanium alloys with unparalleled precision and uniformity. 

Our research team delved into fundamentals of the titanium nanotube growth on alpha and beta phase alloys, controlled manufacturing of TNT in linear and circular alignments and their corrosion analysis in SBF solutions. We further aim to research TNT growth in enhancing efficiency of biomedical implants and optical applications.

Alongside the electrochemical anodization setup, we boast a state of the art potentiostat dedicated to corrosion analysis, facilitating comprehensive studies on material degradation mechanisms and corrosion resistance properties. Researchers and students within our laboratory have the opportunity to delve into the intricacies of electrochemical processes, exploring the vast potential of nanomaterials for a multitude of industrial applications.