Rotating Flat-Nozzle Cavitation Processing for Faster Surface Smoothing

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Solution Overview

Problem

Conventional cavitation surface processing methods are limited by slow grinding speeds.

Innovation Solution

A method involving the suspension of abrasives in processing liquid, use of a rotating flat spray nozzle to eject a cavitation jet in a plane or helical ribbon shape, and application of compressive residual stress through abrasive collisions with the workpiece surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional cavitation processing method is used, then surface smoothing and peening can be achieved, but grinding speed is slow

Engineering Contradiction:

Improvegrinding speedVSAvoidsurface quality consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The spray nozzle is rotated at 100-200 RPM to dynamically generate a helical ribbon-shaped cavitation jet that spreads in a plane on the workpiece surface. This dynamic approach increases the effective grinding area and improves material removal rate while maintaining surface quality through controlled cavitation collapse patterns.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The cavitation jet is transformed from a conventional one-dimensional stream into a two-dimensional planar spreading pattern through the rotating nozzle mechanism. This dimensional expansion allows simultaneous processing of larger surface areas and increases the number of abrasive collisions with the workpiece surface, thereby improving grinding speed.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If cavitation jet is ejected to smooth surface, then surface roughness is reduced, but processing time increases

Engineering Contradiction:

Improvesurface roughnessVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The rotating nozzle maintains continuous cavitation jet ejection across the entire workpiece surface without interruption. The helical ribbon-shaped jet ensures uninterrupted abrasive collision and cavitation collapse, providing continuous useful action that reduces processing time while maintaining surface quality.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The spray angle is optimized to 5-10 degrees about the ejection axis, and the nozzle rotation speed is controlled at 100-200 RPM. These parameter optimizations ensure that the cavitation jet maintains optimal orientation and energy distribution for efficient surface smoothing while minimizing processing time.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If abrasive particles are used to increase grinding speed, then material removal rate increases, but control of residual stress becomes difficult

Engineering Contradiction:

Improvematerial removal rateVSAvoidresidual stress control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The conventional mechanical abrasion system is replaced with a cavitation-based processing system where cavitation collapse generates micro-jets and shock waves that facilitate controlled abrasive collision. This substitution allows higher material removal rates while maintaining control over residual stress through the fluid-mediated interaction mechanism.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The cavitation jet acts as an intermediary between the abrasive particles and the workpiece surface. It controls the delivery and collision of abrasives, enabling optimized material removal while maintaining control over the processing parameters that govern residual stress distribution.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Increases the grinding speed and efficiency of surface smoothing by enhancing abrasive collisions and residual stress application.

Implementation Method 1

ejecting a cavitation jet spreading in a plane on a surface of the workpiece

Methodology Applied

Scientific EffectCavitation: Cavitation

Implementation Method 2

entraining abrasives by the cavitation jet to collide with a target surface which is a surface of a workpiece

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 3

applying a compressive residual stress on the target surface by the cavities being collapsed near the target surface

Methodology Applied

Scientific EffectCavitation collapse: Cavitation

Data Source

PatentUS20250381646A1Cavitation surface processing method

Publication Date: 2025.12.18 SUGINO MACHINE

AI summary

The cavitation processing method increases the grinding speed of the surface. The cavitation surface processing method, includes: suspending abrasives into processing liquid; immersing a workpiece and a flat spray nozzle into the processing liquid; ejecting a cavitation jet spreading in a plane on a surface of the workpiece while the flat spray nozzle is rotating about an ejection axis; and smoothing the surface of the workpiece to apply a compressive residual stress on the surface of the workpiece.