GOALI/Collaborative Research: Mechanics and Dynamics of Low Frequency Vibration Assisted Machining

GOALI/合作研究：低频振动辅助加工的力学和动力学

基本信息

批准号：
2019370
负责人：
Burak Sencer
金额：
$ 20.16万
依托单位：
Oregon State University
依托单位国家：
美国
项目类别：
Standard Grant
财政年份：
2020
资助国家：
美国
起止时间：
2020-09-01 至 2024-08-31
项目状态：
已结题

来源：
https://www.nsf.gov/awardsearch/showAward?AWD_ID=2019370&HistoricalAwards=false
关键词：
GOALI Collaborative Research Mechanics Dynamics

项目摘要

This Grant Opportunities for Academic Liaison with Industry (GOALI) project partners two universities with industry in the fundamental research on the effect of applying slow vibrations to enhance material removal in machining processes. Vibrations have been treated as a disturbance and a source of inefficiency to many manufacturing operations including machining processes. However, this new approach attempts to use low frequency (slow) vibrations to improve the contact conditions between the cutting tool and workpiece and thereby improve machining efficiency. By applying controlled slow oscillations to cutting tools, this new cutting process can enable material removal with lower cutting effort and energy, attain longer tool-life, and improve overall stability of the machining process towards higher material removal rates. It can significantly enhance manufacturing productivity, and hence US competitiveness and prosperity, and product quality especially for components made of difficult-to-cut metal alloys employed in U.S. automotive, aerospace, defense and energy sectors. Collaboration with a partner from US automotive industry will help ensure the technology transfer and enhance student training.This project investigates the mechanisms by which low frequency vibration applied in continuous cutting process can alter and improve the cutting mechanics and dynamics. Modulating the tool at low frequency along tool feed direction transforms continuous cutting into discrete cutting. This new discrete cutting kinematics not only alters the deformation mechanics of chip formation, but also changes the thermomechanical dynamics in the cutting zone as well as the dynamic stability of the machining process. This research will analyze chip formation mechanics through in-situ digital image correlation and develop analytical models to understand the relationship between vibration kinematics, including cutting force and energy, and overall material removal effort. As the low frequency modulation periodically disengages the cutting tool from the workpiece, it interrupts continuous heating of the cutting edge and induces pre-determined cool-down periods to reduce tool temperature. Analytical models and experimental characterization will capture this transient and cyclic heat conduction regime and its thermo-mechanics. It will provide optimal cutting strategies to increase the tool-life. Finally, effect of feed modulation on the coupled dynamics of process and the machining equipment will be investigated. New knowledge will be created on how to use the controlled low frequency vibration to control and suppress high-frequency self-excited chatter instabilities during machining. It will allow machining of precision parts at significantly higher depth, feed and speed leading to greater material removal rates.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.

这种与工业联络（Goali）的学术联络机会的授予机会合作了两所工业大学，这些大学在基础研究中，对应用缓慢振动以增强加工过程中的材料去除的效果。振动已被视为包括加工过程在内的许多制造运营的干扰和效率低下的来源。但是，这种新方法试图使用低频（慢）振动来改善切割工具和工件之间的接触条件，从而提高加工效率。通过将受控的缓慢振荡应用于切割工具，这种新的切割过程可以通过降低切割和能量来清除材料，从而实现更长的工具寿命，并提高加工过程的总体稳定性，以降低较高的材料去除率。它可以显着提高制造生产率，因此，美国竞争力和繁荣以及产品质量，尤其是针对由美国汽车，航空航天，国防和能源领域的难以切割的金属合金制成的组件。与美国汽车行业的合作伙伴的合作将有助于确保技术转移并增强学生培训。该项目研究了在连续切割过程中应用低频振动可以改变和改善切割机制和动态的机制。沿着工具进料方向调节工具以低频调节工具将连续切割变成离散切割。这种新的离散切割运动学不仅改变了芯片形成的变形力学，而且还改变了切割区中的热机械动力学以及加工过程的动态稳定性。这项研究将通过原位数字图像相关性分析芯片形成力学，并开发分析模型，以了解振动运动学之间的关系，包括切割力和能量以及整体材料去除工作。随着低频调制会定期从工件中脱离切割工具，它会中断尖端的连续加热，并诱导预定的冷静时期以降低刀具温度。分析模型和实验表征将捕获这种瞬时和循环热传导状态及其热力学。它将提供最佳的切割策略来增加工具寿命。最后，将研究饲料调制对工艺耦合动力学和加工设备的影响。将创建有关如何使用受控的低频振动来控制和抑制加工过程中高频自激发不稳定性的新知识。这将允许在更高的深度，饲料和速度上加工精度零件，从而导致更高的材料去除率。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审查标准通过评估来获得支持的。