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Automated Production of High Precision Copper Accelerator Structure Cells--Robertson Precision, Inc., 2971 Spring Street, , Redwood City, CA 94063-3935; 650-363-2212
Mr. William B. Robertson, Principal Investigator
Mr. Craig Poulsen, Business Official
DOE Grant No. DE-FG03-98ER82657
Amount: $750,000
The construction of the DOE’s Next Linear Collider (NLC) for the high energy physics community requires a high volume manufacturing process that can use conventional machines to produce precision accelerator cells. To further reduce manufacturing costs, the substrates from which the cells are made must be produced so as to minimize any final machining (via diamond turning). This project will develop and demonstrate a precision manufacturing method, utilizing a high end, conventional, multi-axis machining center, that is optimized for the production of NLC accelerator cells. The machining center will be housed in a temperature-controlled environment and will be integrated with off-the-shelf automation equipment. Phase I demonstrated that a conventional metalworking lathe used in a temperature-regulated environment has sufficient process accuracy and repeatability to enable its use for the production of precision copper accelerator cells for the NLC. Both batch and sequential manufacturing was demonstrated for the production of parts. In Phase II, the single spindle lathe will be replaced with a twin spindle/twin turret manufacturing center. Ultimately, an automated process will be optimized for the manufacture of ultra-precision accelerator cells of varied dimensions.
Commercial Applications and other Benefits as described by the awardee: A fully automated, precision manufacturing process should contribute to increased yield and to the improvement of quality components throughout the aerospace, optical, electronics, and medical industries. Repeatable high precision manufacturing should also result in cost reductions, leading to a lower final cost of components in these industries.