GOALI: Investigation of High-Speed Face Milling of Difficult-to-Cut Materials with Minimum Quantity Lubrication Using High Oleic Soybean Oil-Based Nanofluids

GOALI：使用高油酸大豆油纳米流体进行微量润滑的难切削材料高速面铣研究

• 批准号: 2218786
• 负责人: Anthony Okafor
• 金额: $ 44.72万
• 依托单位: Missouri University of Science and Technology
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2022
• 资助国家: 美国
• 起止时间: 2022-09-01 至 2025-08-31
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2218786&HistoricalAwards=false
• 关键词: GOALI; Investigation; Speed; Face; Milling

This Grant Opportunity for Academic Liaison with Industry (GOALI) award supports research that will build knowledge about a more sustainable and eco-friendly method of machining difficult-to-cut materials used in aerospace and automotive industries. These materials, such as Inconel 718, are problematic to machine due to the shear force and heat generated by the high friction between tool and workpiece, which leads to rapid tool wear and low productivity. Conventional cooling techniques used for machining flood the area with an emulsion coolant, causing issues like high coolant consumption and disposal problems. This award supports fundamental research to investigate alternative cooling and lubrication strategies based on a minimum quantity lubrication approach and using nanoparticle-filled soybean oil-based fluids. Minimum quantity lubrication employs a small amount of lubricant and compressed air to form an aerosol, which is sprayed in mist form through a nozzle to lubricate and cool the cutting zone, avoiding the problems and costs associated with the conventional emulsion flood method. The new cutting fluids can replace conventional ones, resulting in a more eco-friendly process with lubricant sourced from local soybean farmers. This research will result in new interfacial engineering knowledge and new cutting force models. The cutting force model will be integrated into virtual machining software for tele-education, and the award will broaden the participation of underrepresented groups in research and engineering education.Low-oleic and high-oleic soybean oils will be employed as base fluids to formulate nanofluids, utilizing surfactants with varying hydrophilic-lipophilic balance and four different nanoparticles, including graphene nanoplatelets. The properties of the nanofluids—including viscosity, thermal conductivity, dispersion stability, coefficient of friction, and mist flow—will be evaluated as a function of temperature, nanoparticle type, and concentration using a suite of material characterization techniques, including spectroscopic methods, dynamic light scattering, rheometry, tribo-rheometry, and thermal conductimetry. The performance of the formulated nanofluids will be evaluated for machining Inconel 718 and compacted graphite iron using a minimum quantity lubrication approach, and benchmarked against the conventional emulsion flood method. Machinability parameters, including cutting force components, tool wear and life, chip morphology, and surface integrity, will be investigated. A mechanistic cutting force prediction model will be established, using specific cutting and edge force coefficients, to understand and predict the best cooling and lubrication strategies. The interdisciplinary expertise of the team in mechanical and chemical engineering, and the industrial partners’ experience in machining and fluid engineering, will be leveraged, while the GOALI partnership will facilitate transfer of research outcomes to the factory floor.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.

这项与行业联络的赠款机会（Goari）奖支持了研究，该研究将建立有关一种难以在航空航天和汽车行业中使用的更可持续和环保的机械方法的知识。这些材料（例如Inconel 718）由于工具和工作场所之间的高摩擦而产生的剪切力和热量，这对机器来说是有问题的，这导致了快速的工具磨损和低生产率。用于加工的常规冷却技术用乳液冷却液淹没了该区域，从而引起了高冷却液消耗和处置问题等问题。该奖项支持基本研究，以根据最低量润滑方法研究替代冷却和润滑策略，并使用充满纳米粒子的大豆基液体进行研究。最小数量润滑的员工少量润滑和压缩空气形成气溶胶，该气溶胶以雾形式喷洒，以润滑和冷却切割区，避免了与常规乳液洪水方法相关的问题和成本。新的切割液可以取代传统的液体，从而产生了来自当地大豆农民的润滑剂，从而产生了更加环保的过程。这项研究将导致新的界面工程知识和新的切割力模型。切割力模型将集成到虚拟加工软件中进行电视教育，该奖项将扩大代表性不足的群体参与研究和工程教育的参与。低油气和高油基豆油将用作基础流体，以形成纳米流体，利用纳米流体，利用基础环境因素，例如繁殖型的繁殖因素，并四分之一纳米片。纳米流体的特性（包括粘度，导热率，分散稳定性，摩擦系数和雾气流）将根据温度，纳米颗粒类型的函数以及使用一套材料表征技术（包括光谱方法，动态光散射，rustry，Rheeottry，Rheotry，Rheotry，Rheotry，rheosry，rheso＆rheSry）来评估。将使用最小数量润滑方法评估配方纳米流体的性能，并使用最小的数量润滑方法进行压实的石墨铁，并针对常规的乳液洪水法进行了标准。将研究可加工性参数，包括切割力组件，工具磨损和寿命，芯片形态和表面完整性。将使用特定的切割和边缘力系数建立机械切割力预测模型，以理解和预测最佳的冷却和润滑策略。团队在机械和化学工程方面的跨学科专业知识，以及工业伙伴在机械和流体工程方面的经验，将掌握，而Goali合作伙伴关系将准备。该奖项反映了NSF的法定任务，将研究成果转移到工厂地板上，并通过使用基金会的知识分子优点和更广泛的影响评估标准来评估，被认为是珍贵的支持。