Ultraprecision Diamond Machining of Conventional Non-Diamond Machinable Materials

传统非金刚石可加工材料的超精密金刚石加工

• 批准号: 7265234
• 负责人: Gang Zhang
• 金额: $ 9.71万
• 依托单位: ECHEMICS
• 依托单位国家: 美国
• 财政年份: 2007
• 资助国家: 美国
• 起止时间: 2007-05-01 至 2007-10-31
• 项目状态: 已结题
• 来源: https://reporter.nih.gov/project-details/7265234
• 关键词: Adsorption; Alloys; Area; Carbon; Chemicals; Computers; Copper; Country; Data; Data Analyses; Development; Devices; Diagnostic; Diagnostic Imaging; Diamond; Drug Delivery Systems; Effectiveness; Equipment; Evaluation; Figs - dietary; Future; Goals; Government; Imaging Device; Life; Materials Testing; Measurement; Measures; Medical; Methods; Microfabrication; Molds; Nature; Nickel; Optics; Persons; Phase; Plastics; Poison; Power Sources; Process; Production; Purpose; Reaction; Research; Research Design; Route; Scheme; Small Business Funding Mechanisms; Small Business Innovation Research Grant; Solutions; Stainless Steel; Standards of Weights and Measures; Steel; Surface; System; Technology; Testing; Titanium; base; catalyst; commercialization; cost; cost effective; electric field; improved; innovative technologies; micro-total analysis system; nanometer; new technology; novel; novel strategies; prevent; prototype; reaction rate; size; success; tool

DESCRIPTION (provided by applicant): Echemics proposes to explore the feasibility of an innovative technology for the diamond machining of the materials that are not conventionally considered to be diamond machinable. Ultraprecision diamond machining such as diamond turning and milling has been widely used to produce optical-quality surfaces, ultra- precisely remove materials, and fabricate microstructures and microdevices with sub-nanometer level surface finishes and sub-micrometer form accuracies. It is an indispensable machining process for fabricating ultraprecision macro- and micro-optics and non-optical components for biomedical products used for biomedicine, biomedical analysis, diagnostics, and treatments. However, one significant drawback of diamond machining is that it can only machine very limited materials called diamond machinable materials. It cannot machine many important materials such as ferrous alloys, stainless steel, titanium and nickel due to catastrophic diamond tool wear. Current technical solutions for extending diamond tool life only achieve limited success; suffer from high cost and complicated setup; and need additional equipment. The chemical reactive wear of diamond tools resulting from the surface-catalyzed reaction between diamond carbon and workpiece (e.g., steel) is one significant tool wear route. However, the current technical solutions have not explored the possibility of manipulating this catalytic reaction. Therefore, this proposal tries to investigate a novel approach to stop or slow down this catalytic reaction so that the high reaction rate can be greatly reduced and tool life can be extended. In this Phase I project, Echemics aims to prove if the proposed technical approach can indeed extend diamond tool life compared with normal diamond machining. If Phase I is successful, Phase II of the project will improve the process and fabricate some prototype biomedical products. As there is an increasing demand for directly diamond machining non-diamond machinable materials for a wide variety of biomedical and other applications, this proposed technology provides a new solution for this call. If successful, Echemics aims to commercialize this novel technology for growing the company and also making the country's ultraprecision manufacturing sector more competitive. This SBIR Phase I project will explore the feasibility of an innovative technology for the ultraprecision diamond machining of the materials that are not conventionally considered to be diamond machinable. Diamond machining is an indispensable machining process for fabricating ultraprecision macro- and micro- optics and non-optical components for biomedical products, including such as diagnostic imaging devices, drug delivery components, implantable components, lab-on-a-chip devices, micro total analysis systems (¿-TAS), and MEMS (MicroElectroMechanical Systems) for biomedicine, biomedical analysis, diagnostics, and treatments. The proposed technology aims to fabricate totally new devices, improve the quality of existing devices, lower manufacturing costs, and become a more universal rapid prototyping tool.

描述（由申请人提供）：化学提出探索一种创新技术的可行性，用于金刚石加工传统上不被认为是金刚石可加工的材料。金刚石车削和铣削等超精密金刚石加工已广泛用于生产光学质量表面，超精密去除材料，以及具有亚纳米级表面光洁度和亚微米形状精度的微结构和微器件。它是制造用于生物医学、生物医学分析、诊断和治疗的生物医学产品的超精密宏、微光学和非光学元件不可缺少的加工工艺。然而，金刚石加工的一个重大缺点是它只能加工非常有限的材料，称为金刚石可加工材料。由于金刚石刀具的灾难性磨损，它不能加工许多重要材料，如铁合金、不锈钢、钛和镍。目前延长金刚石刀具寿命的技术方案成效有限；成本高，设置复杂；还需要额外的设备。金刚石刀具的化学反应磨损是金刚石碳与工件（如钢）表面催化反应产生的一种重要的刀具磨损途径。然而，目前的技术解决方案还没有探索操纵这种催化反应的可能性。因此，本提案试图研究一种新的方法来阻止或减缓这种催化反应，从而大大降低高反应速率，延长工具寿命。在这个一期项目中，Echemics的目的是证明所提出的技术方法与普通金刚石加工相比是否确实可以延长金刚石刀具的寿命。如果第一期项目成功，第二期项目将改进工艺并制造一些生物医学产品原型。由于生物医学和其他应用对金刚石直接加工非金刚石可加工材料的需求日益增加，该技术为这一需求提供了新的解决方案。如果成功，Echemics的目标是将这项新技术商业化，以发展公司，并使该国的超精密制造业更具竞争力。这个SBIR一期项目将探索一种创新技术的可行性，用于超精密金刚石加工传统上不被认为是金刚石可加工的材料。金刚石加工是制造用于生物医学产品的超精密宏、微光学和非光学部件不可或缺的加工工艺，包括诊断成像设备、药物输送部件、可植入部件、片上实验室设备、用于生物医学、生物医学分析、诊断和治疗的微总体分析系统（¿- tas）和MEMS（微机电系统）。提出的技术旨在制造全新的设备，提高现有设备的质量，降低制造成本，并成为一种更通用的快速原型工具。