Two-Dimensional Cutting of Polycrystalline Diamond and CBN Tools and Dies using a Novel Laser/Waterjet Hybrid Manufacturing Process

使用新型激光/水射流混合制造工艺对多晶金刚石和 CBN 工具和模具进行二维切割

• 批准号: 1000035
• 负责人: Pranav Shrotriya
• 金额: $ 37.57万
• 依托单位: Iowa State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2010
• 资助国家: 美国
• 起止时间: 2010-05-01 至 2014-04-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1000035&HistoricalAwards=false
• 关键词: Two; Dimensional; Cutting; Polycrystalline; Diamond

The objective of this project is to test the following two hypotheses: 1) the combined action of laser and waterjet will result in development of tensile stresses perpendicular to cutting path and propagation of cracks along cutting path during the two-dimensional cutting and 2) if the material removal mechanism were changed from thermal melt and evaporation (laser cutting) or material erosion (electrical discharge machining) to material separation through crack propagation, then smaller kerf; parallel walls; higher cutting speed and substantial energy savings can be attained in the machining of two-dimensional profiles of polycrystalline diamonds and polycrystalline cubic boron nitride over conventional machining processes. The project's approach is to test the hypotheses relies on fundamental fracture mechanics modeling and experiments to investigate controlled fracture of superhard materials due to thermal and chemical effects of laser heating and waterjet quenching.Successful completion of the research activities will lead to a novel machining method for brittle materials along with a detailed understanding of the fundamental underpinnings behind this new process. This novel hybrid manufacturing process will have potential to offer high performance tools and dies for metal cutting and wire drawing industries respectively. Automotive, woodworking and other industries that use synthetic diamond tools would greatly benefit from this research. Education and outreach outcome will include training of graduate students in advanced manufacturing research, assimilation of the research outcomes into new course modules, the involvement of undergraduates from underrepresented groups in the research team and the dissemination of the research results through journal publications, conferences and industry visits and workshops.

该项目的目的是测试以下两个假设：1）激光和水射流的联合作用将导致二维切割过程中垂直于切割路径的拉应力的产生以及裂纹沿切割路径的扩展；2）如果材料去除机制从热熔化和蒸发（激光切割）或材料侵蚀（放电加工）转变为通过裂纹扩展进行材料分离，然后是更小的切缝；平行墙；与传统加工工艺相比，加工多晶金刚石和多晶立方氮化硼的二维轮廓可以实现更高的切削速度并显着节省能源。 该项目的方法是测试依赖于基础断裂力学模型和实验的假设，以研究由于激光加热和水射流淬火的热和化学效应而导致的超硬材料的受控断裂。研究活动的成功完成将带来一种新颖的加工方法脆性材料以及对这一新工艺背后的基本基础的详细了解。 这种新颖的混合制造工艺将有潜力分别为金属切削和拉丝行业提供高性能工具和模具。 汽车、木工和其他使用人造金刚石工具的行业将从这项研究中受益匪浅。 教育和推广成果将包括对研究生进行先进制造研究的培训、将研究成果纳入新的课程模块、让代表性不足群体的本科生参与研究团队以及通过期刊出版物、会议和行业传播研究成果参观和研讨会。