GOALI: Improved Tool-Path Design to Reduce Assembly Costs of High-Speed-Machined Wrought and Additive Metal Parts

目标：改进刀具路径设计以降低高速加工锻造和增材金属零件的装配成本

• 批准号: 1762722
• 负责人: Arif Malik
• 金额: $ 45.84万
• 依托单位: University of Texas at Dallas
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2018
• 资助国家: 美国
• 起止时间: 2018-07-15 至 2022-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1762722&HistoricalAwards=false
• 关键词: GOALI; Improved; Tool; Path; Design

This Grant Opportunity for Academic Liaison with Industry (GOALI) project provides the fundamental research needed to significantly improve the quality of aluminum parts used in aircraft production. These high-value parts are made by cutting complex shapes out of large blocks of aluminum on high-speed milling machines. Because all parts need to fit perfectly when assembled into an aircraft, it is critical that they have very precise dimensions. When parts fail to assemble correctly, significant delays and cost overruns are incurred by the aerospace industry because of re-work and scrap. Furthermore, the demand for more precise parts creates significant technical and economic burdens on the machine shops that make them. Therefore, this research project aims to create new high-speed machining techniques that improve part quality, raise production rates, and reduce material losses. In addition to helping the aerospace industry, machine shops in the United States will benefit from the project as they currently face costly trial-and-error when manufacturing aircraft parts. As such, this project directly aids in economic welfare and national security, since the aerospace and machining industries are strongly tied to both. Knowledge from the research will also help spur competitive new manufacturing, such as the machining of 3D-printed metal parts. The participation of diverse students in this project (including a disabled veteran) as well as the exposure of engineering education to teens with autism, will provide for valuable educational and societal impacts.The research goal is to investigate initial residual stress distributions in wrought and additively manufactured aluminum alloys, and how this knowledge can lead to new tool-path designs that improve dimensional tolerances for high-speed-machined parts. The technical approach involves combining inverse Cauchy stress prediction, machining-induced residual stress modeling, and residual stress measurements to determine whether initial residual stresses cause dimensional distortions in monolithic aluminum parts to a greater extent than the aggregated thermal, wear, and machining effects. Crack compliance tests, neutron diffraction, and high-density point-cloud geometry mapping of feature-rich monolithic parts will be used to identify residual stress patterns that regularly exist in wrought aluminum materials prior to machining. Knowledge of the residual stresses will be used to design new stress-compensated tool-paths for high-speed machining processes. Contributions of the research include: knowledge regarding residual stress patterns and their effect on geometric deviations during high-speed machining; new statistical inference techniques that combine inverse stress predictions with experimental measurements to characterize residual stresses as random fields; and methods to design new stress-compensated stochastic machine tool-path trajectories. Besides their significance in improving high-speed-machining operations, the developed research techniques will also be tested on emerging hybrid (additive/subtractive) manufacturing processes.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

这项与工业联络的赠款机会（Goali）项目提供了显着提高飞机生产中使用的铝制零件质量所需的基础研究。这些高价值零件是通过从高速铣床上的大块铝制切出复杂形状来制成的。因为所有零件都需要在组装成飞机时完美拟合，所以至关重要的是它们具有非常精确的尺寸。当零件无法正确组装时，由于重新工作和废料，航空航天行业产生了重大延误和成本超支。此外，对更精确的零件的需求在使它们的机械车间上造成了巨大的技术和经济负担。因此，该研究项目旨在创建新的高速加工技术，以提高零件质量，提高生产率并减少材料损失。除了帮助航空航天行业外，美国的机械车间将从该项目中受益，因为他们目前在制造飞机零件时面临昂贵的试用和纠正。因此，该项目直接有助于经济福利和国家安全，因为航空航天和加工行业都与两者息息相关。研究的知识还将有助于刺激有竞争力的新制造业，例如3D打印金属零件的加工。 The participation of diverse students in this project (including a disabled veteran) as well as the exposure of engineering education to teens with autism, will provide for valuable educational and societal impacts.The research goal is to investigate initial residual stress distributions in wrought and additively manufactured aluminum alloys, and how this knowledge can lead to new tool-path designs that improve dimensional tolerances for high-speed-machined parts.技术方法涉及将倒数库奇应力预测，加工诱导的残余应力建模和残余应力测量结合，以确定初始残留应力是否会导致整体铝部件的尺寸扭曲，而不是聚集的热，磨损和加工效应。裂纹合规测试，中子衍射和高密度点云的几何形状映射将使用富特征单片的零件来识别加工之前在锻炼铝材料中经常存在的残留应力模式。对残余应力的了解将用于设计用于高速加工过程的新应力补偿工具路径。该研究的贡献包括：有关残留应力模式的知识及其对高速加工过程中几何偏差的影响；将反应力预测与实验测量相结合的新统计推理技术将残留应力表征为随机场；以及设计新的应力补偿随机机床轨迹轨迹的方法。除了改善高速手机运营方面的重要性外，开发的研究技术还将在新兴的混合动力车（添加/减法）制造过程中进行测试。该奖项反映了NSF的法定任务，并被认为是值得通过基金会的知识分子优点和更广泛的影响审查审查标准来通过评估来通过评估来获得支持的。

项目成果

Improved grain structure prediction in metal additive manufacturing using a Dynamic Kinetic Monte Carlo framework

• DOI: 10.1016/j.addma.2020.101649
• 发表时间: 2020-10
• 期刊: Additive manufacturing
• 影响因子: 11
• 作者: Sumair Sunny;Haoliang Yu;Ritin Mathews;A. Malik;Wei Li

Simulation of laser impact welding for dissimilar additively manufactured foils considering influence of inhomogeneous microstructure

• DOI: 10.1016/j.matdes.2020.109372
• 发表时间: 2021
• 期刊: Materials & Design
• 影响因子: 8.4
• 作者: Sumair Sunny;Glenn Gleason;Ritin Mathews;A. Malik

Numerical investigation elucidating effects of microstructure on the transient thermomechanical phenomena during laser impact welding

• DOI: 10.1016/j.jmapro.2022.04.031
• 发表时间: 2022-07
• 期刊: Journal of Manufacturing Processes
• 影响因子: 6.2
• 作者: Glenn Gleason;Sumair Sunny;Ritin Mathews;A. Malik

Effects of microstructure and inherent stress on residual stress induced during powder bed fusion with roller burnishing

• DOI: 10.1016/j.ijmecsci.2022.107092
• 发表时间: 2022-02-09
• 期刊: INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
• 影响因子: 7.3
• 作者: Sunny, Sumair;Mathews, Ritin;Malik, Arif
• 通讯作者: Malik, Arif

Coupling between inherent and machining-induced residual stresses in aluminum components

• DOI: 10.1016/j.ijmecsci.2021.106865
• 发表时间: 2021-10
• 期刊: International Journal of Mechanical Sciences
• 影响因子: 7.3
• 作者: Ritin Mathews;Sumair Sunny;Arif Malik;Jeremiah Halley