SBIR-STTR Award

This Small Business Technology Transfer (STTR) Phase I project will develop an innovative application for modulation-assisted machining (MAM) technique to increase the productivity of deep-hole drilling of micro/meso-scale features in the production of high-performance biomedical components. A prototype process will be demonstrated thayt can be easily achieved on aexisting computer-controll;ed machines. In this process, a controlled, low-frequencty vibration (modulation) is superimposed onto the machining process, creating a series of discrete cutting events that are controlled with remarkable effectiveness by the modulation parameters, leading to easy chip removal. The process will also enhance the effectiveness of lubrication, enabling the machining to be performed with minimal use of cutting fluids. When implemented in the appropriate framework, the proposed technology will result in a class of highly efficient, clean machining processes that will impact applications above and beyond the biomedical component manufacturing, to aerospace and automotive sectors. The anticipated reduction in the use of cutting fluids will make the process environmentally friendly. The partnership with the University will provide students excellent opportunity for education and training.

This Small Business Technology Transfer (STTR) Phase II project aims to develop a Modulation-Assisted Machining (MAM) system with novel capabilities for micro/meso-scale deep-hole drilling of biomedical components. The system is structured around a new device; an accessory developed for computer numerically controlled (CNC) machine tools. This new device superimposes a low-frequency sinusoidal modulation onto machining processes enabling controlled chip formation and easy disposal, enhanced lubrication of tool-chip contact, reduces energy consumption, and, potentially, a reduction in tool wear. When implemented in the appropriate system framework, unprecedented increases in productivity and efficiency of deep-hole drilling processes are envisaged. The broader impact/commercial potential of this project will be commercialize MAM technology in manufacturing of biomedical components and related applications in automotive and aerospace fluid systems manufacturing. Complemented by a strong education and training program. By driving the development of a class of clean machining processes with reduced effluent streams and energy consumption, and improved efficiency, this project will impact sustainable manufacturing for the discrete products sector, with broad societal benefits.