SBIR Phase II: Ultrahigh Speed Micromachining Spindle

这个小型企业创新研究（SBIR）二期项目旨在开发用于微加工的超高速微主轴。拟议的微铣削和微磨削主轴的速度接近50万rpm，将在现有的商业微加工系统中实施。微制造是指使用各种材料制造高精度三维（3D）产品，其尺寸范围从几十微米到几毫米。虽然微尺度技术在半导体和微电子领域已经建立了良好的基础，但对于制造涉及复杂3D几何形状和非硅材料高精度的产品来说，情况却并非如此。工业和军事产品要求小型化、设计灵活性、降低能耗和高精度的趋势继续加速，特别是在医疗、生物技术、电信和能源领域。所提出的微主轴的主要优点包括通过实施超高速加工获得更高的生产率和精度，这将减少切削力和刀具振动。原型微主轴将在商业微加工系统的一系列alpha和beta测试中进行评估。第二阶段的目标是进行必要的研发，为微型主轴的市场营销做准备。本项目的广泛影响/商业潜力包括以下方面：超高速微主轴将使生产具有成本效益的微元件成为可能，并将对微制造行业产生积极影响。由于在如此高的速度下进行微加工的基本科学原理尚不清楚，因此所提出的主轴的可用性将允许进行基础研究，以揭示材料在这些条件下的响应。这些基本信息可能会导致新的科学发现，并进一步扩展微加工工艺。所产生的数据和信息无疑将在未来用于培养研究生。本研究的广泛影响包括微制造研究的扩展，以及下一代科学研究人员和技术开发人员在微定位装置、微模具制造、微传感和监测系统以及微工厂集成和优化等更广泛领域从事微加工和微制造相关工作的研究机会。拟议的微铣削主轴的商业化将有助于发展新的商业和工业，以及高附加值的就业机会。

This Small Business Innovation Research (SBIR) Phase II project is directed towards the development of an ultrahigh speed micro-spindle for micro-machining. The proposed spindle for micro-milling and micro-grinding at speeds near 500,000 rpm will be implemented with existing commercial micro-machining systems. Micro-manufacturing refers to the creation of high-precision three-dimensional (3D) products using a variety of materials and possessing features with sizes ranging from tens of micrometers to a few millimeters. While micro-scale technologies are well established in the semiconductor and microelectronics fields, the same cannot be said for manufacturing products involving complex 3D geometry and high accuracies in non-silicon materials. The trends in industrial and military products that demand miniaturization, design flexibility, reduced energy consumption, and high accuracy continue to accelerate -- especially in the medical, biotechnology, telecommunications, and energy fields. The principal advantages of the proposed micro-spindle include higher production rates and precision obtained through the implementation of ultrahigh speed machining that will decrease the cutting forces and tool vibrations. The prototype micro-spindle will be evaluated in a series of alpha and beta testing with commercial micro-machining systems. The objective of Phase II is to perform the necessary R&D to prepare the micro-spindle for marketing.The broader impact/commercial potential of this project encompasses the following. The ultrahigh speed micro-spindle will enable the production of cost-effective micro-components and will positively impact the micro-fabrication industry. Since the underlying scientific principles of micromachining at such high speeds are not known, the availability of the proposed spindle will allow for basic studies to uncover the response of materials under these conditions. Such basic information could lead to new scientific discoveries and further extend the micromachining processes. The data and information generated will undoubtedly be used in future for training of graduate students. The broad impact of this research includes expansion of micromanufacturing research, and research opportunities for next-generation scientific researchers and technology developers to pursue micro machining and micro manufacturing related efforts in the broader fields of micro positioning devices, micro die-and-mold manufacturing, micro sensing and monitoring systems, and micro factory integrations and optimization. Commercialization of the proposed micro-milling spindle will be instrumental in the development of new businesses and industries, and high value added jobs.