I am working on gridded ion thrusters.Presently we are using 1mm thick and 100 mm dia disk for beam extraction which has around 1000 1-2mm holes in it.
The manufacturing of the grids is a difficult task.The present grid were made by conventional drilling but it still has sharp burrs and edges in the holes.Laser drilling was also tried but it causes a bend in the material due to residual stresses after it cools.
I wish to know is there any process available for manufacturing grid with perfect holes without any distortion or misalignment.
Regards,
Try conventional drilling with sacrificial top and bottom layers of the same material. @ Bharat Singh Rawat
For me the best option is to use electric discharge drilling. The unique problem is that this process is slow, but can drill autonomously, without human attention.
Also, in RG there are some papers over how is possible to reduce the exit burr using conventional drills.
Article Study on Mechanism of Burr Formation in Drilling
Article Simulation of Drilling Process for Control of Burr Formation
Article Experimental analysis of burr formation in drilling of TI-6AL-4V alloy
Article Reduction of Burr Formation in Drilling Using Cryogenic Proc...
And there are many works in this sense.
I have another idea. And if you try by fiber laser, but with the material submerged in water?
Article Mechanism of Recast Removal During Laser Drilling Underwater
Another possibility to eliminate the entrance burr is to use a stepped drill.
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