SBIR Phase I: Reduced-Friction Cutting Tools for Increased Productivity via Micro-Fluidic Lubrication (MFL)

SBIR 第一阶段：减少摩擦切削刀具，通过微流体润滑 (MFL) 提高生产率

• 批准号: 0512811
• 负责人: William Endres
• 金额: --
• 依托单位: Endres Machining Innovations
• 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 2006-03-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0512811&HistoricalAwards=false
• 关键词: SBIR; Phase; Reduced; Friction; Cutting

This Small Business Innovation Research Phase I project will address the feasibility of cutting tools with micro-geometric features to provide lubrication where it will be most effective. The innovation includes the new micro-fluidic lubrication (MFL) features as well as a commercial production process for high-volume manufacture of cutting inserts exhibiting MFL features. Mechanical machining processes are used in the manufacture of many products. Modern cutting tool materials, including diamond and cubic-boron-nitride, are the hardest known and are becoming routinely used. However, they are very expensive compared to tungsten carbide, the performance of which can be enhanced with alloying and coatings to reduce its tendency to chemically dissolve into the chip and work piece at high temperatures. Unfortunately, all these substrate materials and modern coatings are already very advanced and will offer little more than incremental improvements in the near future. This project will addresses the productivity (cutting speed) limitation imposed by thermally induced wear, by reducing the heat source on the tool. It is anticipated that this new approach will allow a doubling of cutting speed for the same wear of the non-MFL case.The broader (commercial) impact of manufacturing MFL inserts would be large given the U.S. market for inserts being about $1.3B, including $900MM in carbide inserts only about $217MM are made in the U.S. (2002 data). "Difficult to machine" materials are seen most in automotive and tool/die manufacturing (hard steel) and aircraft manufacturing (titanium and nickel-based alloys). Cutting tool expenditures for these industries in 2004 were about $370MM and $55MM, respectively. Capturing only 10% of engine machining, and 40% of the others, revenues would be $95MM.This project could be useful in meso-scale machines.

这个小型企业创新研究第一阶段项目将探讨具有微几何特征的刀具的可行性，以便在最有效的地方提供润滑。这项创新包括新的微流控润滑(MFL)功能，以及用于大批量制造具有MFL功能的刀片的商业生产工艺。许多产品的制造都采用机械加工工艺。现代刀具材料，包括钻石和立方氮化硼，是已知的最硬的，正在成为常规使用。然而，与碳化钨相比，它们非常昂贵，碳化钨的性能可以通过合金化和涂层来增强，以减少其在高温下化学溶解到芯片和工件中的倾向。不幸的是，所有这些衬底材料和现代涂层都已经非常先进，在不久的将来只会带来渐进的改进。该项目将通过减少刀具上的热源来解决由热致磨损造成的生产率(切割速度)限制。考虑到美国的刀片市场价值约为13亿美元，其中9亿美元的硬质合金刀片只有约2.17亿美元在美国制造(2002年数据)，因此制造MFL刀片的更广泛的(商业)影响将是巨大的。“难加工”材料在汽车和工具/模具制造(硬钢)和飞机制造(钛和镍基合金)中最常见。2004年，这些行业的刀具支出分别约为3.7亿美元和5500万美元。仅获得10%的发动机加工，以及40%的其他收入，收入将是95美元。这个项目可能对中规模的机器有用。