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R D Proposal MPCST
R D Proposal MPCST
9. Budget Estimate
(A) Non-Recurring (Equipment, please attach three quotations)
S. Name of Equipment/Facilities Specifications of No. of Units Estimated cost as
No. to be procured equipment on date (Rs.)
1.
2.
Sub-Total "A"
(B) Recurring
S. Item Year-wise Proposed Budget Total
st nd rd
No. 1 Year 2 Year 3 Year
1. Fellowship of JRF/SRF/Field Astt.
2. Consumables
3. Travelling Exp.
4. Publication/Printing
5. Contingency (Please specify)
Sub-Total "B"
Grand Total A+B (Total Project Cost):
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DECLARATION & ATTESTATION
I/We have read the terms and conditions for MPCST research grants. Necessary Institutional
facilities will be provided if the research proposal is approved for financial assistance. I a l s o
declare that no funding is applied or taken from any other agency for the
s a m e / s i m i l a r p r o j e c t . Audited statement of expenditure and utilization certificate along with
annual progress report will be submitted by the Institution at the end of the year (from the date of
sanction of the project). Final Technical Report and complete Utilization Certificate will be
submitted at the end of the project.
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position to execute or complete the project, it may be required to refund the entire amount
of grant with interest received by it, to the Council.
8. The Council reserves the right to terminate the grant at any stage and also to recover
the amounts already paid with interest, if it is convinced that the grant has not been
properly utilized or the work on the Project has been suspended or appropriate progress is
not being made.
9. The Project will become operative with effect from the date of receipt of the first
installment of the project grant by the grantee institution.
10. If the Investigator to whom a grant for a Project has been sanctioned leaves the Institution
where the Project is being implemented, he/she shall submit five copies of complete and
detailed report of the work done by him/her on the Project and the money spent till the
date of his/her relieving from the institution. The institution shall also arrange to refund
the unspent balance, if any.
11. The account of the sanctioned project of all grantee institution shall be open for
inspection by the Council.
12. The Grantee Institution is liable to refund entire grant with interest if they do not abide by
any condition specified in the Agreement.
13. The Council has right to physical verification of work performance at the cost of Grantee
Institution.
14. The PI / grantee institution shall submit annual progress report along with utilization
certificate and statement of expenditure and shall submit final technical report at the end of
the project.
15. The PI/Institution shall recruit the project fellow/JRF at the earliest possible and furnished
complete process of recruitment including copy of advertisement, minutes of selection
committee, appointment order of fellow and joining.
16. The grantee institute shall follow the norms and guidelines of MPCST for submission of
number of proposals as per guidelines available on the Councils website.
17. A cancelled cheque of the Institution comprising details for electronic payment of the project
grant should be attached with the proposal.
18. The Grantee Institution / PI shall follow the government rules/norms as applicable from
time to time.
Signature of Co-Investigator
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SECTION – B BIODATA OF THE INVESTIGATORS
This Field is Mandatory
(Use separate sheets for Principal
Investigator & Co-Investigator)
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13. Professional Recognition/ Awards/Prizes/Certificates etc. won by the
Candidate:
Place:
Date:
Signature of the Principal Investigator
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SECTION – C - DETAILED RESEARCH PROPOSAL
This information must be adequate and sufficiently self-contained to enable the
Council and the Referee to assess the project, and it must cover the following aspects:
a) Review of work done in India in the area of project proposed along with
reference citation.
The research work µ-USM was not revealed from literature; however, few significant
studies on micro-machining using conventional USM were reported. A brief account of
such research work is presented in subsequent section. The research work on the micro-
machining using conventional USM was initiated in India in the 2010. A team of
researchers from IIT Roorkee conducted experiments on borosilicate glass micro-slides for
machining of open micro-channels. Although the machine used for this study was a
conventional USM, the reported surface quality and dimensional accuracy can be
considered as good. The machined micro-channels were as narrow as 120 µm [19]. Further,
micro-holes of 300 µm diameter were drilled on borosilicate glass. In all such studies the
size of abrasive particles used was small, 1 µm in general. The effect of process parameters
on different quality characteristics in micro-machining is different. It had been reported that
effect of static load is higher on MRR, whereas effect of abrasive particle size is more on
TWR [20]. The above-mentioned literature reveals that USM can be successfully utilized
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for machining of hard, brittle and even tough materials. Many investigators have advocated
the practical and economic benefits of using conventional USM for micro-channels.
However, it is a proven fact that surface roughness is dependent on depth of cut [21]. This
implies that surface quality obtained may vary in a nonlinear fashion with increase in depth
of cut. Such a variation may lead to inconsistencies with process outcomes. A machining
process can only fulfill requirements for machining of 3D- micro-moulds, if there is an
absolute control on input process parameters. Micro-machining with conventional USM
may result in significant differences in dimensions of machined workpiece at entry and exit.
These differences may be attributed to large tool size used in conventional USM. The use of
large sized abrasive particles (20-40 µm) in conventional USM also contributes to
deviations in desired surface quality and dimensional tolerances. In this respect, researchers
had proposed the use of small particles size abrasives (1-5 µm) in conventional USM for
micro-machining. However, these smaller abrasives on 20 kHz frequency of vibration (in
conventional USM) may get more travel time from tool surface to workpiece surface.
Further, the mass of these smaller abrasives is less and they may stray off owing to
combined effect of more travel time and slurry flow rate. These strayed abrasives (in
conventional USM) may not be effective in material removal at workpiece, however may
lead to inaccuracies on the machined surface. Thus, it will be a good proposition to increase
the frequency of vibration from 20 kHz to 40 kHz to improve a better accuracy and precise
control on abrasive action. The frequency of vibration in conventional USM should be
resonant with amplitude for maximum penetration. USM transducers seldom provide high
frequency and high amplitude simultaneously as this may result in excessive heating of
transducer. Thus, there exist a manufacturing limitation and therefore transducers which
operate at high frequency provide lower amplitudes. This manufacturing limitation in case
of proposed µ-USM can be a boon as better control of material removal on workpiece can
be possible at lower amplitudes. The machining of 3-D microstructures using µ-USM in
India was not revealed from literature. Thus, development of µ-USM, as a machining
process, especially in Indian context is a requirement, which is yet to be fulfilled. Further,
any initiative from the potential manufacturing industries was not revealed, which could be
benefited most by the µ-USM.
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b) Review of work done abroad in the area of project proposed along with
reference citation.
An extensive amount of research has been done in the area of conventional USM. The
focuses of these research works, in general, are investigations based on process outcomes
(tool wear, surface finish, material removal rate and dimensional accuracy). However, the
research on µ-USM is still in process. In mid 1990’s, first research work on µ-USM was
revealed from literature [9]. In this research work, micro-machining of 150 µm thick glass
sheet for micro-turbine using µUSM was reported by a team of Japanese researchers.
Further, geometrical capability of developing 3-D surfaces, blind holes and slots was
verified using µ-USM [10]. The tolerances and dimensional accuracy in µ-USM are of
utmost importance. This accuracy depends on dimensions and accuracy of micro-tools used
in µ-USM. Thus, newer fabrication methods for micro-tools were identified. One such
method for fabrication of micro-tools was use of wire electric discharge grinding (WEDG).
Thus, successful drilling of 20 µm precise hole in silicon plate by µ-USM was reported
[11]. A new method for µ-USM was developed in which vibrations were given to the
workpiece keeping the tool stationary. This method was able to drill micro-holes of 5 µm in
quartz glass and silicon [12]. In another research the influence of tool diameter and tool
rotation was studied on machining of glass using Tungsten Carbide tools [13]. The rotation
of the tool in µ-USM increased the machining speed [14]. The increase in static load also
increases tool wear in µ-USM [15]. It was reported that surface roughness achieved in µ-
USM is dependent on depth of cut [16]. This implies that further investigation is required
for obtaining desired surface quality in machining of 3-D micro-structures by µ-USM. The
relative movement of tool and workpiece and its control defines the quality of machining
complex cavities. Thus, integration of CAD/CAM with µ-USM was attempted [17].
Further, force measurement and controller system had been developed to avoid cutting force
overshoot [8, 18].
c) Justification for taking up the proposed project, highlighting the gap in the
existing knowledge in the field.
Micro-components have several applications in the electronics, robotics, biomedical
implants etc. Miniaturization of components is the need of the hour because it saves space,
material and power consumption. Thus, extensive research focus is on development of
faster and economical ways of micro-fabrication. Micro-machining is a subtractive
technology for micro-fabrication of micro-components of size in the range of 1 to 500
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micrometers. Some of the practical examples of micro-machining include drilling of 60-
micron holes in 1mm thick hardened steel for diesel injector nozzles [1]. Silicon wafers
have been successfully micro machined to cut small channels which have been used in
micro fluidics applications [2]. These micro-channels have replaced the conventional
circular tubes in automotive condensers [3]. A number of parallel machined micro-channels
have been used to develop micro coolers used in MEMS devices [4]. The development of
micro fuel cell systems has been achieved by the fabrication of micro-channels. In the
medical field, an infusion micro-pump has been developed for drug delivery for the
treatment of neurological disorders and pain management, [5]. Some micro-machines
developed can travel inside the human body through the blood vessels and heal the
damaged areas [6]. Apart from this flying micro-robot have been developed for defence and
spying purposes [7]. The processing techniques that have found extensive application in
industry for micro-fabrication are photolithography, etching, LIGA (lithography,
electroplating, and molding) and laser ablation. Photolithography, etching and LIGA are
quite time consuming and are not considered as eco-friendly methods. Further, these
techniques are unable to manufacture 3-D components and have a limited application on
few materials. Laser ablation is quite versatile and fast process but it does not provide
economic advantage. Moreover, it causes thermal damage on the surface. Thus, a need
exists for development of a process which can manufacture 3D shapes and still remain
economical. The micromachining using proposed micro-ultrasonic machining (µ-USM) can
fulfill above mentioned requirements. The µ-USM is derived from conventional ultrasonic
machining (USM), which is an established industrial process for machining hard and brittle
materials. Similar to USM, the proposed µ-USM will be a simple process (in terms of lesser
processing steps) and will have economical advantage over photolithography, etching,
LIGA and laser ablation. Further, µ-USM can generate 3D shapes with no thermal damage.
The µ-USM however has higher frequency (above 20 KHz) and lower amplitude (0.5-
5µm) than conventional USM. Further, the size of abrasive particles in µ-USM is in few
microns (0.5- 5µm) [8].
d) Justification of the project with the likely impact of the proposed investigation
(scientific/technological/industrial on regional economic growth/overall
welfare/ generation of competence.
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e) Preliminary work already done by PI/Co-PI on the topic of proposed project
including details of project (if any).
f) The scientific/technological significance of undertaking this investigation
and expected output/outcome.
The Expected outcomes are as follows:
1. The novelty and findings from this project work will encourage the deployment in
micro-ultrasonic machining as well as micro-machining of hard and brittle materials
and economical ways of micro-fabrication. The key findings will be published in
SCI indexed Journal.
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Phase – IV
Phase – III
Phase wise activities
Phase – II
Phase – I
0 2 1 3 3 3
Time in months
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4. Budget Estimate
(A) Non-Recurring (Equipment, please attach three quotations)
S. Name of Equipment/Facilities Specifications of No. of Units Estimated cost as
No. to be procured equipment on date (Rs.)
1.
2.
Sub-Total "A"
(B) Recurring
S. Item Year-wise Proposed Budget Total
st nd rd
No. 1 Year 2 Year 3 Year
1. Fellowship of JRF/SRF/Field Astt.
2. Consumables
3. Travelling Exp.
4. Publication/Printing
5. Contingency (Please specify)
Sub-Total "B"
Grand Total A+B (Total Project Cost):
Consumables
The major part of consumables will be abrasives and workpiece material. This material
consists of Boron Carbide abrasives and Silicon wafers which have to be imported and are
pretty costly. For the micromachining very precise hardware is required and to support that
a solid and steady base is essential. The base is free from any type of vibration and whole of
the micro set up is housed within. Stainless steel will be used to develop structure of the
machine and the fixture for clamping the workpiece.
Travel
Traveling will be required regarding procurement of material, collection of resource
materials etc.
Contingencies
Contingencies are required for fabrication of the tooling system, collection of resource
materials, printing, publication etc.
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REFERENCES
Undertaking
I/We have read the terms and conditions of research grant and agree to abide by the
same.
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