Any Practical Experience with Micro-wire Cutting?

What - like a piercing saw, for example?

That's what I had in mind of using, but I never did any cutting with micro wires.

I'd make a jig to get an accurate cut. but I have now idea on how accurate these cut, the link in my original post shows approx. life of the wire, but not much on what it was cutting. with 0.005" wire, I would plan on cutting it in an abrasive solution or cutting speed. But I have no experience with this, and I'd like to bounce it off here, even if I get a no way in heck.

This being a hobby, I'm always looking for ways to make it on my budget. unfortunately sometimes my budget gets out of hand, which if it meets my goal I can over look that.

Silicon wire cutting

look through these, some use wire

Budget? what budget?

http://www.laddresearch.com/general-laboratory-supplies/wire-saw-model-l850

on the main post, had a link similar.... only it was about $14,000.00 did up to 2" dia.

I only put that there that I did make an attempt (feeble one at that) before I brought it to CR4.

Well it shows there is a method...you need a SS wire and diamond dust or silicon carbide or boron carbide powder for a slurry mix...and then you'll need to build a jig for the process...make a wire loop with precision guidance, dc motor drive with controls....good luck

https://www.a-msystems.com/p-772-stainless-steel-wire.aspx

http://multimedia.3m.com/mws/media/1011853O/3m-boron-carbide-abrasive-grains-and-powders.pdf

EDM?

Laser?

Multipart construction of said component?

Without knowing the exact material and application you won't get much for solid answers.

'I have this thing and I need to do something with it to make it work for something else. Any ideas on how to make it build it and make it work?'

That's about what I am getting out of this so far.

I saw the possibility of an EDM. Even as I'm looking for this process, I've come across different ways of doing it including precision stamping, but I didn't care for the pieces.

Being the first prototype, I've even received quotes for contracting it out. I even came across things off the shelve that's unconventional, but it could work.

This post is just to bounce this around, and I'm getting pretty good ideas in an indirect way.

Machine as a donut and a flat headed peg. Interference fit. Make a washer of aluminium

.005" thick, squeeze together. Place it a strong solution of potassium hydroxide(KOH), with stirring, to etch away the aluminium.

Assuming the metal will resist KOH? There you have the finished piece with the gap. Clean it with a fine mono-filament, or nylon thread

You could flux and tin the two pieces, wipe clean, assemble, heat to solder the donut and peg together, adding solder to the nip, and then etch

wow, that's interesting.

I think I already found a solution for the proto type, but I'll diffidently keep that in mind.

Thanks, as things develop I'll let you guys know... don't expect anything soon. I'm using the local tech college machine shop on the more intricate work, and its hard to get scheduled.

thanks

I only saw them offer a 0.010" wire saw, do they have finer one?

I do not think so, but I could be wrong that lasers could be set up to cut specimens in any sort of comparable way, and the surface produced would likely not be near as smooth, but Solar Eagle will probably prove me wrong on this one too. But hey, I am here to learn, and get lucky and contribute something once in a while.

yes, 0.005" stainless, but its not coated. you have to cut in a solution.

so basically it drags the abrasive along with? Or is the solution an etchant for the material in question? IF etching, the wire supposedly will continuously refresh some solution that must be exhausted at the boundary layer.

yep, just like the Egyptians

You MIGHT find someone willing to try a .005 wire EDM.

Typical wire dia. is .010 for a .012 kerf.

I wasn't too familiar with EDM, I'd keep it in mind.

The process is performed in a fluid bath if that matters.

I've seen it, and understand the basics, with it basically replaceing the mold maker and tool and die maker to an extent. But I don't really know it's capability.

Any way to design the device to not need such a fine groove of such depth in it?

If it was me I would be trying machine it as two pieces that press fit together. One has a .005" shoulder and one does not.

That's what I'm doing, it just that I require quite a few. Doing it at the local tech college machine shop lab. Unfortunately, I can only get lab time on the manuals, and last Tuesday, I did a few to get the procedure down. Next time it'll go better.

it be great if the CNC lab wasn't booked solid. Otherwise it would only take a evening.

As far as a procedure, I Don't know if it even really exists yet. But, being this as a hobby (that's how I justify it) I like to do as much as I can on my own. Just to establish proof of concept Proto-type. If it's works out, I don't mind spending to get it right.

My immediate thought was EDM (Wire cutting) with a jig that revolved the piece to create the cylindrical cutdown.

The other though is a three piece process with a shaft 0.63" and outer sleeves at 1.75" and then use hot sleeve, cold shaft to get a tight fit. Gap then easily set with feeler/shims during assembly. This makes all components easily fabricated with no consraints on internal machined radius if try to use two part assembly.

If absolute concentricity is a concern, could "finish" outer surface after assembly.

I'm also interested in how intended user plans to clean/service this slot if it becomes fouled. They will need some service strategy for that slot?

If absolute concentricity is a concern, could "finish" outer surface after assembly.

I'm also interested in how intended user plans to clean/service this slot if it becomes fouled. They will need some service strategy for that slot?

Good comments, and nice thinking beyond the problem especially with the little info I gave.

with the design that I started and even the newer one I'm leaning toward, It's address already, as things proceed I'll report back on the progress. But it wouldn't be too soon.

I'll be busy this weekend developing for my next machine shop lab to start again. Yes, back to the drawing board. By stepping back and relooking at the problem, I actually found off the shelf parts I can refit and use.

So I have to design these into my project.