Grantee Research Project Results
Final Report: Low-Cost Machining Without Cutting Fluids
EPA Contract Number: 68D03042Title: Low-Cost Machining Without Cutting Fluids
Investigators: Rozzi, Jay C.
Small Business: Creare Incorporated
EPA Contact: Richards, April
Phase: II
Project Period: May 1, 2003 through April 30, 2005
Project Amount: $224,865
RFA: Small Business Innovation Research (SBIR) - Phase II (2002) Recipients Lists
Research Category: Nanotechnology , SBIR - Nanotechnology , Small Business Innovation Research (SBIR)
Description:
The goal of this research project was to develop and commercialize Creare Incorporated’s Cutting Tool Cooling System (CUTS). CUTS indirectly cools cutting tools, eliminates the need for conventional cutting fluids, and prolongs tool life. As a result, this innovation provides a less-costly machining process that is environmentally friendly. This novel, low-cost, flexible system is a prevention-oriented solution to the environmental and occupational health problems posed by cutting fluids.
Creare Incorporated worked to develop a novel, low-cost, flexible solution to the environmental, occupational health, and machining performance problems posed by cutting fluids. Creare integrated CUTS into a real-world manufacturing operation and facilitated the acceleration of CUTS to a commercial product. To complete this effort, work was divided into prototype design, fabrication and integration, testing and evaluation, and design for manufacture. In addition, commercialization activities were initiated with a key alliance partner.
Summary/Accomplishments (Outputs/Outcomes):
Phase II clearly demonstrated the technical and commercial viability of Creare’s innovative system. CUTS is a paradigm shift in manufacturing, enabling the cost-effective and environmentally friendly machining of a variety of common materials. The following was achieved during this research project:
- Development of a portable version of Creare’s cutting tool cooling system envisioned for a small machine shop.
- Validation of the performance of this system using thorough testing at Creare over a range of materials. For stainless steel, Creare confirmed that CUTS extends the tool life by as much as 700 percent, while eliminating the need for conventional machining coolants. This performance translates to dramatic cost reductions and improved worker health and safety.
- Demonstration that CUTS can be applied to a wide range of materials during off-site testing. During these demonstrations, which included Ti-6Al-4V and Aluminum 6061, CUTS equaled or bettered the performance of standard coolants. For titanium, Creare’s system extended the tool life by more than 160 percent, demonstrating the usefulness of this system for hard, aerospace alloys.
- Completion of a detailed cost analysis of this system to facilitate commercialization.
- Completion of commercialization activities with Creare’s alliance partner.
Conclusions:
Creare achieved all of the goals for this research project. Creare integrated CUTS into current machining operations and accelerated the transition of this novel device to a commercial product. In short, CUTS proved to eliminate the need for costly and unsafe coolants, while improving machining performance. Eventual integration of this innovation onto the manufacturing floor will greatly enhance the environmental friendliness of manufacturing operations in small shops, while extending the manufacturing capability and reducing costs.
Creare has recognized four significant markets for CUTS technology insertion:
- Environmentally friendly machining systems. Based on the results of this research project, Creare demonstrated that such a system is technically feasible and commercially viable.
- Vision-based control of machining processes. The elimination of flood or jet coolants opens the door for vision-based control for large-scale manufacturing processes or the processing of hazardous materials.
- High-performance machine tool systems for advanced materials processing. Combining this technology with advanced cutting tools will increase their ability to withstand the high-cutting forces associated with difficult-to-machine materials, such as ceramics, titanium, superalloys, ceramic-matrix composites, and metal-matrix composites. The use of this technology will enable faster, more accurate processing of these materials for a wide variety of engineering applications.
- Ultra-high accuracy machining using precise cutting tool temperature control. A CUTS system coupled to an appropriate control strategy would enable precise thermal control for high-accuracy machining.
Supplemental Keywords:
machining, cutting fluids, Cutting Tool Cooling System, CUTS, machine shop, stainless steel, tool life, aluminum, titanium, aerospace alloys, SBIR,, Scientific Discipline, INTERNATIONAL COOPERATION, TREATMENT/CONTROL, Sustainable Industry/Business, cleaner production/pollution prevention, Environmental Chemistry, Technology, New/Innovative technologies, pollution prevention, Environmental Engineering, cutting fluid alternative, cleaner production, dry machining, environmentally conscious manufacturing, environmentally friendly technology, clean technologies, clean technology, green engineering, cutting fluids, machining, synthetic coolant, innovative technology, tool cutting, industrial innovationsSBIR Phase I:
Low-Cost Machining Without Cutting Fluids | Final ReportThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.