Erosive jet micro-machining and vibratory surface finishing: optimization and modeling

侵蚀喷射微加工和振动表面精加工：优化和建模

• 批准号: RGPIN-2014-03608
• 负责人: Spelt, Jan
• 金额: $ 2.84万
• 依托单位: University of Toronto
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2017
• 资助国家: 加拿大
• 起止时间: 2017-01-01 至 2018-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=638597
• 关键词: Erosive; jet; micro; machining; vibratory

The proposed research pertains to two manufacturing processes: A) erosive jet micro-machining and B) vibratory surface finishing. Both processes involve the controlled application of erosion to remove material, and can also be used to change the surface properties of metals, ceramics and plastics. Erosive jet micro-machining uses either high-speed jets of air with abrasive particles (abrasive jet micro-machining, AJM) or jets of water with abrasive particles (abrasive slurry jet micro-machining, ASJM). Both techniques have great potential as versatile, low-cost, environmentally-friendly approaches to the fabrication of small-scale features that are difficult to make with traditional techniques such as milling and acid etching. Potential applications span an extremely wide range from aerospace (e.g. turbine blades) to components used in micro-fluidics, optoelectronics and microelectronics. Moreover, AJM and ASJM do not involve hazardous etching chemicals, and do not suffer from tool wear, vibration, or heating. The proposed research will explore the possibility of the AJM of glass and ceramic components without the use of erosion resistant masks, in a “direct-write” mode. This would be a major breakthrough in reducing costs and machining times, but the blast zone needs to be more highly focused to make this a reality. ASJM can already make smaller features, since it uses a liquid abrasive slurry jet, and we plan to extend our existing work on the use of long-chain polymer additives in the abrasive slurry to increase the focusing of the jet. This will be of significant value in the proposed research on the micro-machining of metallic components, particularly those advanced ultra-hard materials that are used to achieve wear resistance and high strength, often at extreme temperatures. These materials are very difficult to micro-machine using other approaches. Therefore, another part of our plan is to explore the possibility that ASJM can be combined with electro-chemical micro-machining (ECM, a type of focused corrosion) to accelerate the rate at which such metallic materials can be machined.Vibratory surface finishing is a widely-used manufacturing process for deburring, polishing, burnishing, texturing, hardening and cleaning metal, ceramic and plastic parts. A bed of solid particles (typical dimension 1 cm) is fluidized using vibrations and develops a circulatory flow into which parts are entrained and become subject to the action of the impacting media. The proposed research will develop models to describe the relationships between the local particle impact velocity and the many process parameters, such as the shape of the particles and the vibrations of the container walls. This information concerning the particle impact velocities is of fundamental importance to the prediction of the rate and extent of surface finishing. This could be of significant benefit given that there are in excess of 2,000 vibratory finishing machines in Ontario alone, used in a wide variety of industries and applications such as removing burrs in steel stampings, parting lines in metal and plastic castings, hardening and texturing in high-voltage electrical connectors, polishing of plastics and metals, and parts cleaning (personal communications with Dr. L. Nichol, Vibra Finish Ltd.). Furthermore, aspects of the research will be applicable to a variety of related processes involving erosive wear and the impact of flowing granular media (e.g. abrasive flow machining, fluidized bed machining, centrifugal disk finishing, polishing and tumbling, drag finishing).

拟议的研究涉及两种制造工艺：A)冲蚀喷射微加工和B)振动表面精加工。这两个过程都涉及到控制应用侵蚀来去除材料，也可以用来改变金属、陶瓷和塑料的表面属性。冲蚀射流微加工采用高速气流和磨粒射流(磨料射流微加工，AJM)或水射流(磨料浆料射流微加工，ASJM)。这两种技术都具有巨大的潜力，可以作为通用、低成本、环保的方法来制造小规模特征，而这些特征是用传统技术(如铣削和酸蚀刻)难以制造的。潜在的应用范围非常广泛，从航空航天(例如涡轮叶片)到用于微流体、光电子学和微电子学的部件。此外，AJM和ASJM不涉及危险的蚀刻化学品，不会受到刀具磨损、振动或发热的影响。这项拟议的研究将探索玻璃和陶瓷组件的AJM的可能性，而不使用耐腐蚀掩模，采用“直接写入”模式。这将是在降低成本和加工时间方面的重大突破，但爆炸区域需要更加高度集中才能使其成为现实。ASJM已经可以制造更小的特征，因为它使用的是液体磨料浆料射流，我们计划扩大我们在磨料浆料中使用长链聚合物添加剂的现有工作，以增加射流的聚焦。这将在拟议的金属部件微加工研究中具有重要价值，特别是那些用于实现耐磨性和高强度的先进超硬材料，通常在极端温度下。这些材料很难用其他方法进行微机械加工。因此，我们计划的另一个部分是探索ASJM与电化学微加工(ECM)相结合的可能性，以加快此类金属材料的加工速度。振动表面精加工是一种广泛使用的制造工艺，用于去毛刺、抛光、抛光、纹理、硬化和清洁金属、陶瓷和塑料零件。固体颗粒床(典型尺寸为1厘米)利用振动使其流态化，并形成循环流动，部分被卷进其中，并受到冲击介质的作用。拟议的研究将建立模型来描述局部颗粒撞击速度与许多过程参数之间的关系，例如颗粒的形状和容器壁的振动。这些关于颗粒碰撞速度的信息对于预测表面抛光的速度和程度是非常重要的。考虑到仅在安大略省就有超过2,000台振动抛光机，用于各种工业和应用，例如去除钢冲压件中的毛刺、金属和塑料铸件中的分型线、高压电气连接器中的硬化和毛化、塑料和金属的抛光以及零件清洗(与Vibra Finish Ltd.的L.Nicholl博士进行私人交流)，这可能是非常有好处的。此外，研究的各个方面将适用于涉及冲蚀磨损和流动颗粒介质的影响的各种相关工艺(例如，磨料流加工、沸腾床加工、离心盘抛光、抛光和滚压、拖动抛光)。