Collaboration in Modeling the Grinding of Silicon Carbide Fiber Reinforced Silicon Carbide Ceramic Matrix Composite

碳化硅纤维增强碳化硅陶瓷基复合材料磨削建模的协作

• 批准号: 1903506
• 负责人: Albert Shih
• 金额: $ 45.82万
• 依托单位: Regents of the University of Michigan - Ann Arbor
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2019
• 资助国家: 美国
• 起止时间: 2019-09-01 至 2024-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1903506&HistoricalAwards=false
• 关键词: Collaboration; Modeling; Grinding; Silicon; Carbide

Advanced materials which can maintain structural strength at high temperature are critically important for the energy efficiency and reliability of the aircraft engines and power generation turbines. The silicon carbide fiber reinforced silicon carbide (SiCf/SiC) is a new generation of material for such high temperature applications. Grinding using diamond abrasive is the final finishing manufacturing processes to achieve the part accuracy and surface integrity. The high-speed contact between the diamond abrasive and the brittle SiCf/SiC material during grinding may generate surface cracks, which will greatly affect the strength and reliability of SiCf/SiC components. Modeling brittle composite materials, to isolate processing conditions where fracture does not occur, is difficult using conventional approaches due to the small size of the reinforcing fibers (diameter about 10 microns) with respect to the bulk material. This research focuses on verifying the feasibility and limitations of using an alternative modeling approach to accurately predict the crack formation and find the damage-free grinding conditions for diamond grinding of SiCf/SiC. If successful the project's modelling approach can be applied to other ceramic reinforced materials and increase the competitiveness of US manufacturing companies servicing aerospace, defense, and energy industries. This research will be conducted in close collaboration with the Laboratory of Machine Tools and Production Engineering, an international leader in grinding research, at RWTH Aachen University in Germany, and aerospace industries within the US. While NSF is only supporting the research conducted in the US, this project enables US researchers to leverage research facilities not available in the US for the benefit of US industries and manufacturing interests. Students engaged on the project will be exposed to international perspectives, and research practices at other esteemed institutes enhancing their workforce readiness. Research findings will also be adopted in the curriculum of manufacturing courses to benefit a broad group of students and inspire the next generation of engineers. This research investigates the ability of the smoothed particle hydrodynamics (SPH) modelling approach to model and gain fundamental understanding of the material removal and damage mechanisms in SiCf/SiC grinding. A comprehensive experimental program will be used to evaluate the modeling outcomes and isolate model limitations. SPH is a particle-based, mesh-free simulation method developed to address technical challenges including the large negative rake angle cutting edge, random orientation and distribution of diamond grains, and large strain and high strain rate deformation and fracture of the SiC fiber, fiber-matrix interface, and matrix. The single grain diamond scratching of SiCf/SiC will first be studied through experiments and SPH modeling to identify SiC material models and SPH techniques. The multi-grain experiment and SPH modeling of the grinding of SiCf/SiC will then be carried out. The damage mechanisms will be investigated to isolate the damage-free diamond grinding conditions for SiCf/SiC. In summary, this research will advance the tools available to gain insights into fundamental knowledge of material removal and damage mechanisms in diamond scratching and grinding of SiCf/SiC and other ceramic matrix reinforced composites.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.

可以在高温下保持结构强度的高级材料对于飞机发动机和发电涡轮机的能源效率和可靠性至关重要。 碳化硅纤维增强碳化硅（SICF/SIC）是用于此类高温应用的新一代材料。 使用钻石磨料进行研磨是实现零件准确性和表面完整性的最终完成制造过程。 研磨过程中钻石磨料和脆性SICF/SIC材料之间的高速接触可能会产生表面裂纹，这将极大地影响SICF/SIC成分的强度和可靠性。 建模脆性复合材料，以分离未发生断裂的处理条件，使用常规方法，由于相对于散装材料的增强纤维的尺寸较小（直径约10微米），因此很难使用常规方法进行建模。这项研究重点是验证使用替代建模方法准确预测裂纹形成的可行性和局限性，并找到无损害的磨削条件，用于SICF/SIC的钻石磨石。 如果成功，该项目的建模方法可以应用于其他陶瓷增强材料，并提高为航空航天，国防和能源行业提供服务的美国制造公司的竞争力。这项研究将与德国rwth Aachen University的国际磨削研究领导者以及美国境内的航空航天工业密切合作，这是与机床和生产工程的实验室。尽管NSF仅支持在美国进行的研究，但该项目使美国研究人员能够利用美国无法获得的研究设施来利用美国行业和制造业利益。 从事该项目的学生将接触到国际观点，并在其他受人尊敬的机构的研究实践中提高他们的劳动力准备。 制造课程的课程还将通过研究发现，以使一群学生受益并激发下一代工程师。这项研究研究了平滑的颗粒流体动力学（SPH）建模方法对SICF/SIC磨削中的材料去除和损坏机制进行基本了解并获得基本了解。 一项全面的实验计划将用于评估建模结果和分离模型限制。 SPH是一种基于粒子的，无网状的仿真方法，旨在应对技术挑战，包括大型负耙角切切，钻石晶粒的随机取向和分布以及SIC纤维，纤维纤维 - 矩阵界面的大应变和高应变速率变形以及裂缝。 SICF/SIC的单粒钻石刮擦将首先通过实验和SPH建模研究，以识别SIC材料模型和SPH技术。然后将进行SICF/SIC磨削的多粒料实验和SPH建模。 将研究损伤机制，以分离SICF/SIC的无损害钻石磨削条件。 总而言之，这项研究将推进可用的工具，以深入了解钻石刮擦和磨损SICF/SIC和其他Ceramic Matrix增强复合材料的基本知识和损害机制。该奖项反映了NSF的立法任务，并通过使用基础的智力效果和广泛的评估来评估，并值得通过评估来进行评估。

项目成果

Experiment and smooth particle hydrodynamic modeling of single-grain diamond scribing of silicon carbide fiber reinforced silicon carbide (SiCf/SiC)

• DOI: 10.1016/j.cirp.2023.04.067
• 发表时间: 2023-06
• 期刊: CIRP Annals
• 作者: Hansen Li;S. Prinz;Yao Liu;P. Mattfeld;A. Shih