SBIR Phase I: Ultrahigh-Pressure Flash Abrasive-Waterjets for Presicion Machining

SBIR 第一阶段：用于精密加工的超高压闪光磨料水射流

• 批准号: 0512066
• 负责人: Peter Liu
• 金额: --
• 依托单位: OMAX Corporation
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2005
• 资助国家: 美国
• 起止时间: 2005-07-01 至 2006-01-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0512066&HistoricalAwards=false
• 关键词: SBIR; Phase; Ultrahigh; Pressure; Flash

This Small Business Innovation Research Phase I project will develop ultrahigh-pressure (UHP) flash abrasive waterjets (FAWJs) to mitigate limitations of non-flashing AWJs on precision machining. AWJs, a cold process and largely material independent, are superior to other tools for drilling large-aspect-ratio small-diameter holes, precision machining, milling, and near-net shaping, particularly for composite, laminates, and alloys such as titanium and inconel. UHP technology has been recognized as one of the mainstream industrial machining tools. However, the nearly incompressibility of water in AWJs, induces anomalies such as microcracking of composites, delamination of laminates, and enlargement of entry-hole diameters. This project will develop FAWJs, through hardware and process development and integration, emulating the phase changing feature of ACJs for reducing material damage and enhancing process precision. The FAWJs would be up to 2 orders of magnitude more cost effective and portable, as well as safer to operate than ACJs. An FAWJ laboratory model will be designed, fabricated and tested to demonstrate the feasibility of performance improvement over AWJs for precision machining.The broader (commercial) impacts from this project will be a novel process to take advantage of the inherent superiority of AWJ machining over other manufacturing processes (e.g., environmentally friendly, ability to handle a wide range of materials, and no added heat in the cutting zone) while mitigating its limitations. The proposed FAWJ will be most suitable for machining complex geometry (e.g., long-aspect-ratio small-diameter and shaped holes) on composites, laminates, and other advanced materials. The FAWJ would meet the urgent demand for high quality and cost-effective machining processes for these materials whose usage has grown rapidly in the aerospace, electronics, and defense industries. Note that the FAWJ can be toggled back and forth to operate in both the flashing and non-flashing modes. Such versatility would further elevate UHP technology to yet another level for precision machining, broadening the basis for the U.S. employment capacity.

该小型企业创新研究第一阶段项目将开发超高压（UHP）闪光磨料水射流（FAWJ），以减轻非闪光AWJ对精密加工的限制。AWJ是一种冷加工工艺，在很大程度上与材料无关，在钻大纵横比小直径孔、精密加工、铣削和近净成形方面上级其他刀具，特别是对于复合材料、层压板和钛和铬镍铁合金等合金。超高压技术已被公认为主流工业加工工具之一。然而，水在AWJ中的几乎不可压缩性，诱导异常，如复合材料的微裂纹，层压板的分层，和入口孔直径的扩大。本项目将通过硬件和工艺的开发和集成，开发FAWJ，模拟ACJ的相变特性，以减少材料损伤，提高工艺精度。FAWJ的成本效益和便携性将比ACJ高出两个数量级，并且操作起来更安全。将设计、制造和测试FAWJ实验室模型，以证明在精密加工中提高AWJ性能的可行性。该项目的更广泛（商业）影响将是一种新工艺，利用AWJ加工相对于其他制造工艺的固有优势（例如，环境友好，能够处理各种材料，并且在切割区域中没有额外的热量），同时减轻其局限性。所提出的FAWJ将最适合于加工复杂几何形状（例如，长纵横比、小直径和异形孔）在复合材料、层压板和其他先进材料上的应用。FAWJ将满足这些材料对高质量和高成本效益的加工工艺的迫切需求，这些材料在航空航天，电子和国防工业中的使用迅速增长。请注意，FAWJ可以来回切换，以在闪烁和非闪烁模式下工作。这种多功能性将进一步将超高压技术提升到精密加工的另一个水平，扩大美国就业能力的基础。