In this study, an AFM-probe based nano-mechanical machining technique is studied to fabricate nano-metric features in the accurate and efficient manner. It uses a retrofitted AFM system with a single crystal diamond probe, whereas external vibration is applied to improve the efficiency and quality of the resulting nano-metric features. The study includes various aspects of AFM-probe based nano-mechanical machining technique such as the vibration frequency, the type of vibration, amplitudes, feed rate and forces associated in the process.

However, the nano-mechanical machining of polymeric nanocomposite materials has several challenges associated with the process, similar to the problems associated with the conventional machining of composite materials. The size of nano-filler materials are comparable to the tip radius of the AFM probe, thus the process of nano-mechanical machining is more complicated due to the inhomogeneous material properties. Such leads to the rapid tool wear, uncut fiber, fiber pull-out or delamination during the nano-mechanical machining process. Thus it is important to understand the mechanics of nano-mechanical machining process specific to nanocomposite materials by identifying its properties.

The material properties of matrix and fillers are well known in their separate entities, but the composite materials often deviate from the ideal sum of the individual matrix and filler material properties due to the interactions between the matrix and filler materials. However, it is difficult to create a realistic analytical or computational model to incorporate all types of molecular interactions possible in nanocomposites.

In this study, the AFM-probe based vibration assisted nano-mechanical machining (VANM) technique is developed, where the vertical and rotational vibrations improved nano-metric machining efficiency. The force model for VANM was also developed for the optimization of process parameters for the desired geometry.

The experimental methods to identify interfacial characteristics between the fibers and matrices in polymeric nanocomposite materials were established as well. The experimental methods include the in-situ AFM scribing of nanocomposite materials as well as the dynamic mechanical analysis (DMA), where the relationship between the composites’ thermomechanical properties and the interfacial characteristics is identified.