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

该奖项支持将抛光单晶金刚石作为制造金刚石微立铣刀的手段的基础研究。研究目的是确定抛光参数（抛光速度、抛光深度、磨料粒度和抛光表面的晶体取向）对平均抛光率、抛光表面粗糙度和抛光工具磨损等工艺结果的影响。具体方法将包括通过实验技术设计进行系统实验，开发抛光过程的简化模型，并通过对不同材料的微加工来评估制造的金刚石微立铣刀的各种特征。教育目标是提高未来的制造业劳动力，并改善现有的制造业课程。具体的方法将是让本科生和研究生，特别是来自代表性不足的群体的学生参与这项研究，并用该项目中获得的知识补充现有的微/纳米制造课程。如果成功，这项研究的好处将包括促进三维微部件和医疗、消费品、军事和电子工业特征的高效和有效的制造。微加工操作将以更可预测的方式实现。常见的问题，如不稳定的力量，较短的刀具寿命，较差的表面光洁度，毛刺形成将被最小化，从而消除了一些最深刻的障碍，阻碍微制造的进一步发展。与工业界的密切合作将使研究/技术迅速转移到工业。由于微制造被视为新兴的制造技术之一，这项研究对于美国保持其制造业竞争力也至关重要。此外，从这项工作中获得的知识将影响钻石在各个领域的新兴应用。

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.