SBIR Phase I: Micro-quantity Internal Cooling (MQuIC) of Cutting Tools for Increased Productivity via Micro-ducts

SBIR 第一阶段：切削刀具的微量内部冷却 (MQuIC)，通过微管道提高生产率

• 批准号: 0512813
• 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=0512813&HistoricalAwards=false
• 关键词: SBIR; Phase; Micro; quantity; Internal

This Small Business Innovation Research Phase I project will develop cutting tools with micro-geometric features to provide direct, localized and evenly distributed cooling of the tool-chip contact zone. This project includes new micro-quantity internal cooling (MQuIC) features as well as a commercial production process for high-volume manufacture of cutting inserts exhibiting MQuIC. 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 addresses the productivity (cutting speed) limitation imposed by thermally induced wear, by concentrating a cooling medium close to the process heat source. The broader (commercial) impact of manufacturing MQuIC 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.

这个小企业创新研究第一阶段项目将开发具有微几何特征的切削刀具，为刀具-切屑接触区提供直接、局部和均匀分布的冷却。该项目包括新的微量内部冷却（MQuIC）功能，以及用于展示MQuIC的切削刀片的大批量生产的商业生产过程。许多产品的制造都采用机械加工工艺。包括金刚石和立方氮化硼在内的现代切削刀具材料是已知最硬的，并且正在成为常规使用。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，所有这些基板材料和现代涂料都已经非常先进，在不久的将来，它们只会有一点点改进。该项目通过将冷却介质集中在靠近加工热源的地方，解决了由热致磨损造成的生产率（切削速度）限制。鉴于美国的刀片市场规模约为13亿美元，其中包括9亿美元的硬质合金刀片（美国仅生产约2.17亿美元（2002年数据）），制造MQuIC刀片的更广泛（商业）影响将是巨大的。“难以加工”的材料见于汽车和工具/模具制造（硬钢）和飞机制造（钛和镍基合金）。2004年，这些行业的切削刀具支出分别约为3.7亿美元和5500万美元。如果只占发动机加工业务的10%和其他业务的40%，收入将达到9500万美元。