Precision Manufacturing of Patterned Beryllium Bronze Leaf Springs via Chemical Etching
Patterned leaf springs made of a beryllium bronze sheet are the key components of certain micro/nano contact probes. The accuracy of the probe is determined based on the precision of the formed pattern. However, a traditional manufacturing method using wire-electrode discharge machining (wire-EDM) i...
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MDPI AG
2018-08-01
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| Series: | Applied Sciences |
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| Online Access: | http://www.mdpi.com/2076-3417/8/9/1476 |
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| author | Rui-Jun Li Peng-Yu Wang Dan-Dong Li Kuang-Chao Fan Fang-Fang Liu Li-Juan Chen Qiang-Xian Huang |
| author_facet | Rui-Jun Li Peng-Yu Wang Dan-Dong Li Kuang-Chao Fan Fang-Fang Liu Li-Juan Chen Qiang-Xian Huang |
| author_sort | Rui-Jun Li |
| collection | DOAJ |
| description | Patterned leaf springs made of a beryllium bronze sheet are the key components of certain micro/nano contact probes. The accuracy of the probe is determined based on the precision of the formed pattern. However, a traditional manufacturing method using wire-electrode discharge machining (wire-EDM) is subject to poor tolerance at the sharp edges and corners. In addition, high energy consumption and costs are incurred for complex patterns. This paper presents a new chemical etching method for the manufacturing of a patterned leaf spring with high precision. Both the principle and process are introduced. Taguchi experiments were designed and conducted and the optimal process parameters were obtained based on the mean value and a variance analysis. Four V-shaped and some other complex patterned leaf springs were successfully fabricated. Comparison experiments concerning the characteristic parameters of the leaf spring were also conducted. The experimental results reveal that the patterned leaf springs manufactured through this method are much better than those achieved using wire-EDM. This manufacturing method can be used to fabricate different high-precision patterned leaf springs or membranes for coordinate measuring machines (CMM) probes and other measuring equipment. |
| first_indexed | 2024-12-13T01:15:09Z |
| format | Article |
| id | doaj.art-57e90a7c881f4d5fb17c98921347250b |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-12-13T01:15:09Z |
| publishDate | 2018-08-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-57e90a7c881f4d5fb17c98921347250b2022-12-22T00:04:21ZengMDPI AGApplied Sciences2076-34172018-08-0189147610.3390/app8091476app8091476Precision Manufacturing of Patterned Beryllium Bronze Leaf Springs via Chemical EtchingRui-Jun Li0Peng-Yu Wang1Dan-Dong Li2Kuang-Chao Fan3Fang-Fang Liu4Li-Juan Chen5Qiang-Xian Huang6School of Instrument Science and Opto-electronics Engineering, Hefei University of Technology, Hefei 230009, ChinaSchool of Instrument Science and Opto-electronics Engineering, Hefei University of Technology, Hefei 230009, ChinaSchool of Instrument Science and Opto-electronics Engineering, Hefei University of Technology, Hefei 230009, ChinaSchool of Instrument Science and Opto-electronics Engineering, Hefei University of Technology, Hefei 230009, ChinaSchool of Instrument Science and Opto-electronics Engineering, Hefei University of Technology, Hefei 230009, ChinaSchool of Instrument Science and Opto-electronics Engineering, Hefei University of Technology, Hefei 230009, ChinaSchool of Instrument Science and Opto-electronics Engineering, Hefei University of Technology, Hefei 230009, ChinaPatterned leaf springs made of a beryllium bronze sheet are the key components of certain micro/nano contact probes. The accuracy of the probe is determined based on the precision of the formed pattern. However, a traditional manufacturing method using wire-electrode discharge machining (wire-EDM) is subject to poor tolerance at the sharp edges and corners. In addition, high energy consumption and costs are incurred for complex patterns. This paper presents a new chemical etching method for the manufacturing of a patterned leaf spring with high precision. Both the principle and process are introduced. Taguchi experiments were designed and conducted and the optimal process parameters were obtained based on the mean value and a variance analysis. Four V-shaped and some other complex patterned leaf springs were successfully fabricated. Comparison experiments concerning the characteristic parameters of the leaf spring were also conducted. The experimental results reveal that the patterned leaf springs manufactured through this method are much better than those achieved using wire-EDM. This manufacturing method can be used to fabricate different high-precision patterned leaf springs or membranes for coordinate measuring machines (CMM) probes and other measuring equipment.http://www.mdpi.com/2076-3417/8/9/1476probeleaf springchemical etchingberyllium bronze |
| spellingShingle | Rui-Jun Li Peng-Yu Wang Dan-Dong Li Kuang-Chao Fan Fang-Fang Liu Li-Juan Chen Qiang-Xian Huang Precision Manufacturing of Patterned Beryllium Bronze Leaf Springs via Chemical Etching Applied Sciences probe leaf spring chemical etching beryllium bronze |
| title | Precision Manufacturing of Patterned Beryllium Bronze Leaf Springs via Chemical Etching |
| title_full | Precision Manufacturing of Patterned Beryllium Bronze Leaf Springs via Chemical Etching |
| title_fullStr | Precision Manufacturing of Patterned Beryllium Bronze Leaf Springs via Chemical Etching |
| title_full_unstemmed | Precision Manufacturing of Patterned Beryllium Bronze Leaf Springs via Chemical Etching |
| title_short | Precision Manufacturing of Patterned Beryllium Bronze Leaf Springs via Chemical Etching |
| title_sort | precision manufacturing of patterned beryllium bronze leaf springs via chemical etching |
| topic | probe leaf spring chemical etching beryllium bronze |
| url | http://www.mdpi.com/2076-3417/8/9/1476 |
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