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This work investigates micro-electro discharge machining (EDM) performance involving deionized and tap water. The chosen machining regime was semi-finishing, where open voltage (from 100 to 130 V) and current values (5–10 A) were applied using a 0.5 µs pulse-on time and a frequency of 150 kHz, i.e., a duty cycle of 25%. First, numerical analyses were performed via COMSOL Multiphysics and used to estimate the plasma channel distribution and melted material, varying the current, sparking gap, electrical conductivity, and permittivity of the two fluids. Then, experimentally, the micro-EDM of holes and channels in hardened thin steel plates were replicated three times for each considered fluid. The material removal rate (MRR), tool wear ratio (TWR), radius overcut, and surface roughness were plotted as a function of open voltage and electrical conductivity. The study proves that as voltage and current increase, the MRR and TWR decrease with electrical conductivity. Nonetheless, for higher electrical conductivity (tap water), the process did not proceed for lower open voltages and currents, and the radius overcut was reduced, contrary to what is commonly acknowledged. Finally, the crater morphology and size were evaluated using a confocal microscope and compared to simulated outcomes. [ABSTRACT FROM AUTHOR]

Through the years, inspiration from nature has taken the lead for technological development and improvement. This concept firmly applies to the design of the antennas, whose performances receive a relevant boost due to the implementation of bio-inspired geometries. In particular, this idea holds in the present scenario, where antennas working in the higher frequency range (5G and mm-wave), require wide bandwidth and high gain; nonetheless, ease of fabrication and rapid production still have their importance. To this aim, polymer-based 3D antennas, such as Dielectric Resonator Antennas (DRAs) have been considered as suitable for fulfilling antenna performance and fabrication requirements. Differently from numerous works related to planar-metal-based antenna development, bio-inspired DRAs for 5G and mm-wave applications are at their beginning. In this scenario, the present paper proposes the analysis and optimization of a bio-inspired Spiral shell DRA (SsDRA) implemented by means of Gielis' superformula, with the goal of boosting the antenna bandwidth. The optimized SsDRA geometrical parameters were also determined and discussed based on its fabrication feasibility exploiting Additive Manufacturing technologies. The results proved that the SsDRA provides relevant bandwidth, about 2 GHz wide, and satisfactory gain (3.7 dBi and 5 dBi, respectively) at two different frequencies, 3.5 GHz and 5.5 GHz. [ABSTRACT FROM AUTHOR]

Micro-manufacturing emerged in the last years as a new engineering area with the potential of increasing peoples' quality of life through the production of innovative micro-devices to be used, for example, in the biomedical, micro-electronics or telecommunication sectors. The possibility to decrease the energy consumption makes the micro-manufacturing extremely appealing in terms of environmental protection. However, despite this common belief that the micro-scale implies a higher sustainability compared to traditional manufacturing processes, recent research shows that some factors can make micro-manufacturing processes not as sustainable as expected. In particular, the use of rare raw materials and the need of higher purity of processes, to preserve product quality and manufacturing equipment, can be a source for additional environmental burden and process costs. Consequently, research is needed to optimize micro-manufacturing processes in order to guarantee the minimum consumption of raw materials, consumables and energy. In this paper, the experimental results obtained by the micro-electrical discharge machining (micro-EDM) of micro-channels made on Ni-Cr-Mo steel is reported. The aim of such investigation is to shed a light on the relation and dependence between the material removal process, identified in the evaluation of material removal rate (MRR) and tool wear ratio (TWR), and some of the most important technological parameters (i.e., open voltage, discharge current, pulse width and frequency), in order to experimentally quantify the material waste produced and optimize the technological process in order to decrease it. [ABSTRACT FROM AUTHOR]

Bio-inspired Dielectric Resonator Antennas (DRAs) are engaging more and more attention from the scientific community due to their exceptional wideband characteristic, which is especially desirable for the implementation of 5G communications. Nonetheless, since these antennas exhibit peculiar geometries in their micro-features, high dimensional accuracy must be accomplished via the selection of the most suitable fabrication process. In this study, the challenges to the manufacturing process presented by the wideband Spiral shell Dielectric Resonator Antenna (SsDRA), based on the Gielis superformula, are addressed. Three prototypes, made of three different photopolymer resins, were manufactured by bottom-up micro-Stereolithography (SLA). This process allows to cope with SsDRA's fabrication criticalities, especially concerning the wavy features characterizing the thin spiral surface and the micro-features located in close proximity to the spiral origin. The assembly of the SsDRAs with a ground plane and feed probe was also accurately managed in order to guarantee reliable and repeatable measurements. The scattering parameter S11 trends were then measured by means of a Vector Network Analyzer, while the realized gains and 3D radiation diagrams were measured in the anechoic chamber. The experimental results show that all SsDRAs display relevant wideband behavior of 2 GHz at −10 dB in the sub-6 GHz range. [ABSTRACT FROM AUTHOR]

This research article describes a technique for realizing wideband dual notched functionality in an ultra-wideband (UWB) antenna array based on metamaterial and electromagnetic bandgap (EBG) techniques. For comparison purposes, a reference antenna array was initially designed comprising hexagonal patches that are interconnected to each other. The array was fabricated on standard FR-4 substrate with thickness of 0.8 mm. The reference antenna exhibited an average gain of 1.5 dBi across 5.25–10.1 GHz. To improve the array's impedance bandwidth for application in UWB systems metamaterial (MTM) characteristics were applied it. This involved embedding hexagonal slots in patch and shorting the patch to the ground-plane with metallic via. This essentially transformed the antenna to a composite right/left-handed structure that behaved like series left-handed capacitance and shunt left-handed inductance. The proposed MTM antenna array now operated over a much wider frequency range (2–12 GHz) with average gain of 5 dBi. Notched band functionality was incorporated in the proposed array to eliminate unwanted interference signals from other wireless communications systems that coexist inside the UWB spectrum. This was achieved by introducing electromagnetic bandgap in the array by etching circular slots on the ground-plane that are aligned underneath each patch and interconnecting microstrip-line in the array. The proposed techniques had no effect on the dimensions of the antenna array (20 mm × 20 mm × 0.87 mm). The results presented confirm dual-band rejection at the wireless local area network (WLAN) band (5.15–5.825 GHz) and X-band satellite downlink communication band (7.10–7.76 GHz). Compared to other dual notched band designs previously published the footprint of the proposed technique is smaller and its rejection notches completely cover the bandwidth of interfering signals. [ABSTRACT FROM AUTHOR]

In this paper, the effect of the micro-electro discharge machining (EDM) milling machinability of Si3N4–TiN workpieces was investigated. The material removal rate (MRR) and tool wear rate (TWR) were analyzed in relation to discharge pulse types in order to evaluate how the different pulse shapes impact on such micro-EDM performance indicators. Voltage and current pulse waveforms were acquired during micro-EDM trials, scheduled according to a Design of Experiment (DOE); then, a pulse discrimination algorithm was used to post-process the data off-line and discriminate the pulse types as short, arc, delayed, or normal. The analysis showed that, for the considered process parameter combinations, MRR was sensitive only to normal pulses, while the other pulse types had no remarkable effect on it. On the contrary, TWR was affected by normal pulses, but the occurrence of arcs and delayed pulses induced unexpected improvements in tool wear. Those results suggest that micro-EDM manufacturing of Si3N4–TiN workpiece is relevantly different from the micro-EDM process performed on metal workpieces such as steel. Additionally, the inspection of the Si3N4–TiN micro-EDM surface, performed by SEM and EDS analyses, showed the presence of re-solidified droplets and micro-cracks, which modified the chemical composition and the consequent surface quality of the machined micro-features. [ABSTRACT FROM AUTHOR]

In this paper, the effect of the micro-electro discharge machining (EDM) milling machinability of Si 3 N 4 -TiN workpieces was investigated. The material removal rate (MRR) and tool wear rate (TWR) were analyzed in relation to discharge pulse types in order to evaluate how the different pulse shapes impact on such micro-EDM performance indicators. Voltage and current pulse waveforms were acquired during micro-EDM trials, scheduled according to a Design of Experiment (DOE); then, a pulse discrimination algorithm was used to post-process the data off-line and discriminate the pulse types as short, arc, delayed, or normal. The analysis showed that, for the considered process parameter combinations, MRR was sensitive only to normal pulses, while the other pulse types had no remarkable effect on it. On the contrary, TWR was affected by normal pulses, but the occurrence of arcs and delayed pulses induced unexpected improvements in tool wear. Those results suggest that micro-EDM manufacturing of Si 3 N 4 -TiN workpiece is relevantly different from the micro-EDM process performed on metal workpieces such as steel. Additionally, the inspection of the Si 3 N 4 -TiN micro-EDM surface, performed by SEM and EDS analyses, showed the presence of re-solidified droplets and micro-cracks, which modified the chemical composition and the consequent surface quality of the machined micro-features.