SBIR Phase II: Development of Subminiature Abrasive-Waterjet Nozzles toward Micromachining

该小型企业创新研究(SBIR)第二阶段项目旨在开发用于50至100微米自动加工特征的微型磨料-水射流技术。挑战在于开发光束直径小于100微米的喷嘴。由于超音速、三相和微流体流动的复杂性，在毛细管控制重力的微型磨料水射流喷嘴中，有几个问题必须解决。所需的磨料尺寸太小，在重力进料下容易结块，流动性差，导致断续进料和频繁的喷嘴堵塞。该公司提出的解决上述问题的新理念已被证明非常有效。与此同时，正在开发新的配件，以进一步缩小喷嘴无法单独完成的特征尺寸。微型磨料喷嘴和附件将安装在多喷嘴平台上，以升级现有的用于微加工和提高生产率的水射流设备，和/或通过将它们与低功率泵和专为低成本微加工量身定做的小占地面积平台相结合，集成到微射流加工中心。该项目的更广泛/商业影响是水射流技术的多功能性(“5M”--从宏观加工到大多数材料的微细加工)是开发低成本微米喷射加工中心的新产品线。为了满足医疗保健系统负担能力的迫切需求，将探索将微型磨料-水射流技术商业化，以低成本制造骨科植入物的生物医学部件。微型磨料-水射流技术还将有利地应用于制造绿色能源产品的零部件和微电子产品。随着全球对微纳技术研发的重视，微纳产品即将商业化。微型磨料-水射流技术将有助于加速该技术的成熟。通过放宽精度要求，微型磨料水射流可以很容易地变成一种负担得起的消费性产品，优于用于制造艺术品、工艺品和珠宝的传统工具。小作坊将受益于成本效益高的微型磨料水射流技术，因为进入微机械加工的初始投资一直成本高昂。

This Small Business Innovative Research (SBIR) Phase II project aims to develop micro abrasive-waterjet technology for automated machining features between 50 to 100 micrometers. The challenge lies in the development of nozzles with beam diameters less than 100 micrometers. Several issues must be resolved due to the complexity of the supersonic, 3-phase, and microfluidic flow through micro abrasive-waterjet nozzles in which capillary dominates gravity. The required size of abrasives is so small that they tend to clump together with poor flowability under gravity feed, causing intermittent abrasive feed and frequent nozzle clogging. New concepts initiated by the company to resolve the above issues has proven to be very effective. In parallel, novel accessories are being developed to further reduce the size of features that cannot be accomplished alone by the nozzles. The micro abrasive waterject nozzles and accessories will be mounted on a multi-nozzle platform to upgrade existing waterjet equipment for micromachining and for enhancing productivity and/or integrated into a micro Jet Machining Center by combining them with a low-power pump and a small footprint platform tailored for low-cost micromachining. The broader/commercial impact of this project is the versatility of waterjet technology ("5M" - from macro to micro machining for most materials) is to develop a new product line of low-cost micrometer Jet Machining Centers. To meet the urgent need for the affordability of the healthcare system, commercialization of micro abrasive-waterjet technology for low-cost manufacturing of biomedical components for orthopedic implants will be explored. The micro abrasive-waterjet technology would also advantageously apply to manufacture components of green energy products and microelectronics. With global emphasis on R&D in micro-nano technology, micro-nano products will be available commercially soon. The micro abrasive-waterjet technology would help accelerate maturing of that technology. By relaxing precision requirements, the micro abrasive-waterjet could readily be turned into an affordable prosumer/consumer product superior to conventional tools for fabricating art, crafts and jewelry. Small job shops would benefit from the cost-effective micro abrasive-waterjet technology since the initial investment for getting into micromachining has been cost prohibitive.