3D Shaping with Tertiary Tool Motion

通过三次工具运动进行 3D 成形

• 批准号: 0600175
• 负责人: Kornel Ehmann
• 金额: $ 39.83万
• 依托单位: Northwestern University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2006
• 资助国家: 美国
• 起止时间: 2006-03-01 至 2011-02-28
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0600175&HistoricalAwards=false
• 关键词: 3D; Shaping; Tertiary; Tool; Motion

The two objectives of this research project are: (1) to conceive an ultra-precision micro/meso-scale machining method for a subclass of three-dimensional free-form surfaces with the concurrent control of their surface topography, and (2) to establish the analytical basis for the process kinematics and cutting mechanics. In the proposed method, primary and secondary motions of a cutting tool are supplemented by a tertiary motion component consisting of controlled small-amplitude closed trajectory motions at ultrasonic frequencies. For the generation of the tertiary motion two alternatives will be explored. The first is based on a piezo-driven two-dimensional flexure design, while the second on a tunable ultrasonic elliptical oscillator. Supporting theoretical work will focus on the analytical formulation of the machine's command sequences for the generation of desired topological features on the surface. Initially, this will be accomplished through geometric and kinematic considerations and later extended to include cutting mechanics related effects such as elastic and plastic deformation, minimum chip thickness influences and others. A prototype machine will be designed, manufactured and tested under different cutting scenarios implemented in conventional and ductile cutting regimes. If successful, the newly conceived micro-cutting process will offer capabilities that cannot be achieved by current competing operations. Its advantages are: (1) very high cutting velocities, (2) ability to impart intricate surface patterns by modulating and phasing the motion components, and (3) creation of sculptured surfaces with controlled topography. The method also offers an alternative to micro-endmilling and eliminates the need for ultra-high-speed low runout spindles. From the scientific standpoint, the combination of theoretical, computational, and experimental methodologies will provide the fundamental understanding of the developed machine's capabilities and of the new processes it executes. Since micro-manufacturing is a fairly new research area, the knowledge base and machine prototype created through this research will provide the necessary educational and physical infrastructure for continued exploration of micro/meso-scale cutting processes.

该研究项目的两个目标是：（1）为了同时控制其表面形貌，以构想一种超精确的微观微/中尺度加工方法，用于三维自由式表面的子类，以及（2）建立过程动力学和切割机制的分析基础。在提出的方法中，切割工具的一级和次要运动是由由受控的小振幅闭合轨迹运动组成的第三纪运动成分补充的超声频率。对于第三运动的产生，将探索两种选择。第一个是基于压电驱动的二维挠曲设计，而第二个是可调超声椭圆振荡器的第二个。 支持理论工作将集中于机器命令序列的分析公式，以生成表面上所需的拓扑特征。最初，这将通过几何和运动学考虑来完成，后来扩展到包括切割机械相关的效果，例如弹性和塑性变形，最小芯片厚度影响等。将在常规和延性切割方案实施的不同切割方案下设计，制造和测试原型机器。如果成功，新构想的微切割过程将提供当前竞争运营无法实现的能力。它的优点是：（1）非常高的切割速度，（2）通过调节和衡量运动组件来赋予复杂的表面模式的能力，以及（3）用受控地形创建雕塑表面。 该方法还提供了微型填充的替代方法，并消除了对超高速度低弹奏纺锤体的需求。从科学的角度来看，理论，计算和实验方法的结合将提供对开发机器能力以及其执行新过程的基本理解。由于微型制造是一个相当新的研究领域，因此通过这项研究创建的知识库和机器原型将提供必要的教育和物理基础设施，以继续探索微型/中间级切割过程。