Fluid Jet Nozzle Modulation for Variable Etch Depth Control
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Solution Overview
Problem
Current fluid jet systems lack the ability to produce parts with variable etch depths accurately and efficiently, as they are limited in modulating the penetration depth of fluid jets based on image data, leading to inconsistent material removal patterns.
Innovation Solution
A fluid jet system equipped with a controller and position actuator that modulates the speed, distance, shape, diameter, abrasive amount, pressure, and angle of the fluid jet nozzle to achieve variable etch depths, driven by digital image data, allowing for precise control of material removal depths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fluid jet systems are used without depth modulation capability, then the system structure remains simple, but the manufacturing precision of variable etch depths is poor
Solution Approach 1:
The patent implements dynamic control of fluid jet parameters during the etching process. The system continuously modulates jet velocity, abrasive concentration, and pressure based on real-time position information to achieve variable etch depths across different regions of the workpiece. This dynamic adjustment capability transforms a static etching system into an adaptive one that can precisely control material removal depth.
Solution Approach 2:
The invention changes multiple physical parameters of the fluid jet simultaneously, including jet velocity, abrasive particle concentration, fluid pressure, and nozzle-to-workpiece distance. By coordinating changes in these parameters, the system achieves precise control over etch depth while maintaining operational efficiency and avoiding excessive system complexity.
2Manufacturing precision
If the fluid jet penetration depth is not modulated, then the processing speed remains high, but the manufacturing precision of variable depths is poor
Solution Approach 1:
The system dynamically adjusts jet velocity and abrasive concentration based on the desired etch depth for each location. By modulating these parameters in real-time during scanning, the system achieves variable depth precision without requiring multiple passes or significant reductions in overall processing speed. The dynamic control allows single-pass variable depth etching.
Solution Approach 2:
The system pre-calculates and pre-sets the parameter modulation profile before etching begins. Based on the digital model of the desired variable depth pattern, the controller determines the optimal sequence of jet velocity, pressure, and abrasive concentration adjustments needed to achieve the target geometry, enabling high-speed precise etching without trial-and-error processing.
3Manufacturing precision
If multiple passes are used to achieve variable depths, then the etch depth precision can be improved, but the productivity decreases
Solution Approach 1:
The system performs preliminary calculation of the complete parameter modulation profile based on the desired variable depth pattern before processing begins. This pre-planning allows the system to execute variable depth etching in a single continuous pass by pre-coordinating all necessary parameter changes, eliminating the need for multiple passes while maintaining high precision.
Solution Approach 2:
The invention maintains continuous etching action throughout the processing by dynamically adjusting parameters during a single uninterrupted scan. The fluid jet continuously removes material at varying depths through real-time parameter modulation, avoiding the idle time and repositioning required by multi-pass approaches, thus maintaining high productivity with precision variable depth control.
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
Enables the production of parts with complex, variable etch patterns corresponding to digital images, enhancing the precision and efficiency of material removal processes.
Implementation Method 1
a fluid jet system includes at least one nozzle configured to emit at least one fluid jet toward a workpiece
Data Source
AI summary
A fluid jet system is configured to etch a workpiece to a plurality of depths to produce an etched part corresponding to a computer image.