Fabrication of Single-Crystal Diamond Micro-Endmills for Micromachining Applications

该奖项支持将抛光单晶钻石作为制造钻石微端铣刀的一种手段的基础研究。研究的目的是确定抛光参数，包括抛光速度、抛光深度、磨粒尺寸和抛光表面的晶体取向对加工结果的影响，包括平均抛光速度、抛光表面粗糙度和抛光工具磨损。具体方法包括通过实验技术的设计进行系统的实验，建立抛光过程的简化模型，以及通过对不同材料上的各种特征进行微加工来评估所制造的金刚石微立刀。教育目标是加强未来的制造业劳动力，并改善现有的制造业课程。具体的方法是让本科生和研究生，特别是来自代表性不足的群体，参与这项研究，并用从这一项目中获得的知识来补充现有的微/纳米制造课程。如果成功，这项研究的好处将包括促进高效和有效地制造用于医疗、消费品、军事和电子工业的三维微部件和特征。微加工操作将以一种更可预测的方式实现。力不稳定、刀具寿命短、表面光洁度差、毛刺形成等常见问题将被最小化，从而消除阻碍微制造进一步发展的一些最深层次的障碍。与工业界的密切合作将使研究/技术能够迅速转移到工业界。由于微制造被视为新兴的制造技术之一，因此这项研究对美国保持其制造业竞争力也是至关重要的。此外，从这项工作中获得的知识将对钻石在各个领域的新应用产生影响。

This award supports fundamental research on polishing single-crystal diamond as a means to fabricate diamond micro-endmills. The research objective is to determine the effects of polishing parameters, including polishing speed, polishing depth, abrasive grain size and crystallographic orientation of the polished surface, on the process outcome, including average polishing rate, polished surface roughness, and polishing tool wear. The specific approach will include conducting systematic experiments through the design of experiments technique, developing a simplified model of the polishing process, and evaluating the fabricated diamond micro-endmills by micromachining various features on different materials. The educational objectives are to enhance the future manufacturing workforce, and to improve the existing manufacturing curricula. The specific approach will be to involve the undergraduate and graduate students, especially from the underrepresented groups, in this research, and to complement the existing micro/nano-manufacturing course with the knowledge gained in this project.If successful, the benefits of this research will include facilitating efficient and effective fabrication of three-dimensional micro parts and features for medical, consumer products, military, and electronics industries. Micromachining operations will be enabled in a more predictable fashion. Common problems such as erratic forces, short tool life, inferior surface finish, and burr formation will be minimized, thereby eliminating some of the most profound obstacles that prevent further development of micro-manufacturing. Close collaboration with industry will enable rapid transfer of research/technology to industry. Since micro-manufacturing is viewed as one of the emerging manufacturing technologies, this research is also critical for the United States to retain its competitiveness in manufacturing. Furthermore, the knowledge gained from this work will impact emerging applications of diamond in various fields.