Facilities

IIT Palakkad has an advanced and compact ultra-precision CNC diamond turning machine procured from Mikrotools Pte. Ltd. (Model: Optima 100). The machine is specifically designed to produce optical mirrors, lenses having spherical and aspherical profiles, multi-lens arrays, mold inserts, freeform and functional surfaces. The machine base is built up of a monolithic natural granite table and it rests on 4-point heavy duty pneumatic passive dampers. The equipment comprise of best in class aerostatic spindle (with crash resistant coated thrust bearing), highly reliable hydrostatic guideway system and ultra-high resolution encoder (34 pm) for superior feedback. The machine is equipped with 3 axis in which X and Y axis have 100 mm traverse each, whereas C axis possess a nominal speed of 4000 rpm. The stiffness and straightness associated with the hydrostatic slide are 500 N/µm and ±0.05 µm/100 mm respectively. Despite having a customized user friendly graphical user interface, the machine also features a high accuracy optic based tool setting device for on- machine measurement. In addition, the ultrasonic elliptical vibration device (UEVC) enables to machine difficult-to-cut materials such as stavax, tungsten carbide, titanium etc to achieve nano-finishing surfaces. The fast tool servo (FTS) utilizes synchronized motion between the spindle and the diamond tool mounted on to high frequency positioning tool post (W-axis) to produce precision contoured surfaces. Form tolerance of 0.5 microns and surface quality of 2nm Ra or less can be achieved with the help of ultra-precision linear and rotary axes.

IIT Palakkad has a CNC Hybrid micromachining center from Mikrotools Pte. Ltd. (Model: DT-110i). DT-110i is a high precision, integrated multi-process machine tool for micromachining. The hybrid machine tool is equipped with several variants of conventional and non-conventional micro machining processes. The available variants include laser beam micromachining (µ-LBM), micro electrical discharge machining (µ-EDM), electrochemical micromachining (µ-ECM), micro wire electrical discharge machining(µ-WEDM) and micro wire electrical discharge grinding (µ-WEDG). In addition, the equipment is capable of doing conventional micro-drilling, micro-milling and micro-turning. The equipment also offers the flexibility to fabricate tool electrodes within the machine itself that can minimize inaccuracies due to clamping and transfer of electrodes. The machine is also able to achieve high accuracy with its on-machine measurement device. Accordingly, the feature allows the controller to compensate for tool wear leading to high accuracy. The base table is designed to have a working surface of 350 mm × 200 mm. The resolution DT-110i is 0.1 µm with an accuracy of ±1 µm / 100 mm and have a repeatability of 1 µm for all axes.

IIT Palakkad comprises of a highly advanced die sink electrical discharge machine (EDM) from Mitsubishi Electric (Model: EA8S). The sinker EDM machine is capable of producing cavities, slots, holes or desired shapes on the workpiece material using a tool electrode having replica of the feature to be produced. The features can be produced with continuous high-quality surface finish and high accuracy (±10 µm). EA8S can even generate a mirror surface finish with an Ra value of ~0.15 µm. Both the tool electrode and workpiece will be submerged in an insulating liquid/dielectric such as hydrocarbon oil during machining. The worktable is designed to move 250 mm in both the X and Y directions, whereas 300 mm in the Z direction. Faster machining can be achieved using EA8S model which offers jump motion of tool electrode and tool electrode rotation. Further, the machine provides additional features including initial machining option for pre-machining workpiece, fuzzy optimization control, auto-stop feature upon undesirable interruption etc. In addition, the system offers control over several process parameters which can be managed using a user friendly software interface Esper advance Pro. Despite the aforementioned features, the auto- programming feature with respect to input conditions, effortless co-ordinate positioning and pneumatic tool holding facility add up to the extensive flexibility of the machine.