Abrasive Fluid Jet Cutting Head for Brittle Materials
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Solution Overview
Problem
Existing abrasive waterjet cutting systems are not well-suited for cutting brittle or fragile materials like printed circuit boards, as they can cause delamination, chipping, and fracturing, and require frequent tool replacement, leading to increased operational costs and environmental hazards.
Innovation Solution
A fluid jet cutting head with a small orifice and jet passageway diameter, combined with a mixing chamber design that allows for precise alignment and continuous abrasive feeding, operates at high pressures to generate a low-load abrasive waterjet, minimizing material damage and optimizing cutting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional abrasive waterjet cutting systems are used, then cutting capability on hard materials is improved, but material damage (delamination, chipping, fracturing) increases when cutting brittle or fragile materials
Solution Approach 1:
The patent changes the physical parameters of the abrasive waterjet system by using superfine abrasives (particle size D90 ≤ 10 μm) and operating at lower pressures (30-60 MPa) compared to conventional systems. This parameter change reduces the jet's penetrative force and mechanical impact, preventing delamination and chipping in brittle materials while maintaining cutting capability through prolonged erosion of the material surface
Solution Approach 2:
The patent applies a specialized nozzle design with specific geometry (conical shape, specific angle) that concentrates the abrasive particles in a controlled manner. The local quality of the jet is optimized to deliver sufficient cutting force at the target point while minimizing lateral dispersion and reduced-force impacts that cause material damage
2Manufacturing precision
If carbide and diamond-coated carbide cutting tools are used, then machining precision is improved, but operational costs increase due to frequent tool replacement
Solution Approach 1:
The patent replaces the mechanical contact cutting system (carbide tools physically engaging the material) with a fluid-based abrasive waterjet system. This substitution eliminates the wear and tear on physical cutting tools, as the abrasive particles are continuously supplied and do not require replacement, thereby reducing operational costs while maintaining machining precision
Solution Approach 2:
The system continuously supplies fresh abrasive particles to the cutting zone, discarding spent abrasives and recovering cutting effectiveness. This eliminates the need to replace worn cutting tools, as the abrasive supply is replenished continuously, maintaining consistent cutting performance without the downtime and costs associated with tool replacement
3Manufacturing precision
If carbide and diamond-coated carbide cutting tools are used, then cutting precision is improved, but environmental hazards increase due to dust generation
Solution Approach 1:
The patent uses a hydraulic fluid stream (water) carrying abrasive particles to perform cutting, replacing the dry mechanical cutting process. The water suppresses dust generation by capturing and transporting material debris away from the cutting zone, eliminating environmental hazards associated with dust while maintaining cutting precision through the controlled abrasive jet
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables precise cutting of brittle materials with reduced delamination and chipping, lower operational costs, and improved environmental safety by using a high-pressure, low-load abrasive waterjet that maintains cutting efficiency and minimizes material damage.
Implementation Method 1
The mixing chamber is configured to receive abrasives to be mixed with the fluid jet generated by the orifice of the orifice mount to form an abrasive fluid jet
Data Source
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Figure 3~3A
AI summary
Fluid jet cutting systems, components and related methods for generating relatively low load abrasive fluid jets that are particularly well suited for cutting fragile, brittle or otherwise sensitive materials are provided. An example method includes supplying fluid at an operating pressure of at least 60,000 psi to an orifice having a circular cross-sectional profile with a diameter that is less than or equal to 0.010 inches to create a fluid jet that leaves a fluid jet cutting head through a jet passageway having a circular cross-sectional profile with a diameter that is less than or equal to 0.015 inches.