GOALI: Six-Sigma Based Robust Process Design Under Tool Deterioration for Giga Fatigue Life of Precision Machined Components in Hard Turning

GOALI：基于 6-Sigma 的稳健工艺设计，在刀具磨损情况下实现硬车削中精密加工部件的千兆疲劳寿命

基本信息

批准号：
0825780
负责人：
Yuebin Guo
金额：
$ 33.78万
依托单位：
University of Alabama Tuscaloosa
依托单位国家：
美国
项目类别：
Standard Grant
财政年份：
2008
资助国家：
美国
起止时间：
2008-08-15 至 2012-12-31
项目状态：
已结题

来源：
https://www.nsf.gov/awardsearch/showAward?AWD_ID=0825780&HistoricalAwards=false
关键词：
GOALI Six Sigma Based Robust

项目摘要

The overarching research objective of this award is to reveal the basic evolution of fatigue life with tool wear progression in hard turning for creating a six-sigma based robust process design. To realize the research objective, a synergistic experimental and theoretical study will be conducted. The research approaches are to: (i) Comprehensively characterize surface integrity evolution versus cutting time and tool wear; (ii) Map the distribution and variance of rolling contact fatigue life onto cutting time and the corresponding tool wear progression; and (iii) Create a six-sigma based robust process design tool for hard turning industry for fatigue life management while maximizing tool life.If successful, the six-sigma based design tool will allow the machining industry to manufacture reliable components while maximizing tool life in production. The new knowledge created will significantly advance the basic understanding of the linkage between process parameters, surface integrity, and product performance. The developed methodology of robust process design will also be useable in broad manufacturing processes when fatigue performance is of concern. This research will benefit machining economics by replacing expensive grinding by cheap and environmentally friendlier turning and reducing the associated tool costs. The synergetic university-industry partnership will afford a unique opportunity for faculty and students through the conduct of research and practical experience in industrial settings. The strong industrial participation will build a long-term research infrastructure through collaboration, co-advising students, industrial seminars, and rapid technology transfer.

该奖项的总体研究目标是揭示硬车削中疲劳寿命随刀具磨损进展的基本演变，以创建基于六西格玛的稳健工艺设计。为了实现研究目标，将进行协同实验和理论研究。研究方法是：（i）全面表征表面完整性演变与切削时间和刀具磨损的关系； (ii) 将滚动接触疲劳寿命的分布和方差映射到切削时间和相应的刀具磨损进程上； (iii) 为硬车削行业创建基于六西格码的稳健工艺设计工具，以进行疲劳寿命管理，同时最大限度地延长刀具寿命。如果成功，基于六西格码的设计工具将允许机械加工行业制造可靠的部件，同时最大限度地延长刀具寿命在生产中。所创造的新知识将显着增进对工艺参数、表面完整性和产品性能之间联系的基本理解。当关注疲劳性能时，所开发的稳健工艺设计方法也可用于广泛的制造工艺。这项研究将通过廉价且环保的车削取代昂贵的磨削并降低相关的刀具成本，从而有利于加工经济。大学与工业界的协同合作伙伴关系将为教师和学生提供在工业环境中进行研究和实践经验的独特机会。工业界的大力参与将通过合作、共同指导学生、工业研讨会和快速技术转让来建立长期的研究基础设施。