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.

该奖学金与工业界的学术联络机会 (GOALI) 奖项支持研究，以建立关于航空航天和汽车行业中使用的难切削材料（例如 Inconel 718）的更可持续、更环保的加工方法的知识。由于刀具和工件之间的高摩擦产生的剪切力和热量，导致刀具快速磨损和低生产率，因此用于加工的传统冷却技术会在该区域充满乳液。该奖项支持基础研究，以研究基于最小量润滑方法和使用少量纳米颗粒填充的大豆油基液体的替代冷却和润滑策略。润滑剂和压缩空气形成气溶胶，通过喷嘴以雾状喷射，以润滑和冷却切割区域，避免了与传统技术相关的问题和成本新型切削液可以取代传统切削液，从而使用来自当地大豆种植者的润滑剂实现更加环保的工艺。这项研究将带来新的界面工程知识和新的切削力模型。集成到远程教育虚拟加工软件中，该奖项将扩大代表性不足的群体对研究和工程教育的参与。低油酸和高油酸大豆油将用作基础油利用具有不同亲水亲油平衡的表面活性剂和四种不同的纳米粒子（包括石墨烯纳米片）配制纳米流体。纳米流体的特性（包括粘度、导热性、分散稳定性、摩擦系数和雾流）将根据以下函数进行评估。使用一套材料表征技术（包括光谱方法、动态光散射、流变测定法、摩擦流变测定法和热学方法）测量温度、纳米粒子类型和浓度将使用最小量润滑方法对配制的纳米流体的性能进行评估，以加工 Inconel 718 和蠕墨铸铁，并以传统的乳化液驱替方法为基准，包括切削力分量、刀具磨损和寿命、切屑形态。和表面完整性，将使用特定的切削和边缘力系数建立机械切削力预测模型，以了解和预测最佳的冷却和润滑策略。将利用该团队在机械和化学工程方面的专业知识以及工业合作伙伴在机械和流体工程方面的经验，而 GOALI 合作伙伴关系将促进研究成果向工厂转移。该奖项反映了 NSF 的法定使命，并已通过使用基金会的智力优点和更广泛的影响审查标准进行评估，认为值得支持。