GOALI: Fundamental Investigation of Constrained Cutting for High Performance Machining of Difficult-to-Cut Materials

GOALI：难切削材料高性能加工约束切削的基础研究

• 批准号: 2323120
• 负责人: Burak Sencer
• 金额: $ 63.07万
• 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: 2024
• 资助国家: 美国
• 起止时间: 2024-07-01 至 2027-06-30
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2323120&HistoricalAwards=false
• 关键词: GOALI; Fundamental; Investigation; Constrained; Cutting

This Grant Opportunity for Academic Liaison with Industry (GOALI) award supports fundamental research on a novel metal cutting method for enhancing the efficiency of machining difficult-to-cut materials. Difficult-to-cut materials have poor machinability in typical machining conditions requiring higher cutting forces, and resulting in higher temperatures, shorter tool life, and poor surface finish. These cutting difficulties are fundamentally attributed to the difficult chip formation characteristics of difficult-to-cut materials and the lack of conventional cutting’s ability to control chip formation. The new cutting method uses a constraining tool in addition to a cutting tool to enable direct control of chip formation during the cutting process. This allows the chip formation characteristics to be optimized, which leads to efficient material removal with lower cutting forces, resulting in longer tool-life, improved surface integrity, and higher material removal rates. The constrained cutting method significantly benefits U.S. manufacturing industries, such as automotive, aerospace and energy, where difficult-to-cut materials are heavily used. Close collaboration with a partner from the U.S. cutting tool industry ensures technology transfer to develop next generation cutting tools and machining strategies. The project generates a well-trained workforce for advanced manufacturing and engineering through the involvement of graduate and under-graduate students, particularly, women and under-represented minorities, in research and education.The research focus of this project is to investigate how geometrically constraining the shear deformation zone affects the mechanics, dynamics, and generated surface integrity of machining processes. Conventional metal cutting processes lack direct control of chip formation. Controlling the shear deformation zone by an additional constraining tool can lead to reduced cutting effort, dramatically improved surface integrity and machining stability. Chip deformation during constrained cutting is analyzed experimentally through in-situ digital imaging and by analytical and computational modelling to understand the fundamental relationship between constraining parameters (location and geometry) and cutting effort (force, energy, and temperature). Constraining the shear deformation zone reduces plastic deformation and thermomechanical loads. This improves surface finish, enhances microstructure, and reduces residual stress. Experimental characterization and correlation with deformation and temperature analysis generate the new knowledge to enable better control of the integrity of the generated surfaces. The effect of constraining tool on the coupled dynamics of the process and the machining equipment is also investigated, which leads to new designs of constraining tool geometries to control and suppress high-frequency self-excited chatter instabilities during machining. This allows machining of precision parts at significantly higher depth, feed and speed leading to greater material removal rates and superior surface finish.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.

该学术与工业联络资助机会 (GOALI) 奖项支持新型金属切削方法的基础研究，以提高难切削材料的加工效率，在需要更高切削力的典型加工条件下，难切削材料的可加工性较差。这些切削困难的根本原因是难切削材料的切屑形成困难以及传统切削缺乏控制切屑形成的能力。新的切削方法除了切削刀具之外还使用约束刀具，可以在切削过程中直接控制切屑形成，从而优化切屑形成特性，从而以较低的切削力实现高效的材料去除，从而获得更长的刀具。 -寿命、提高的表面完整性和更高的材料去除率使美国制造业受益匪浅，例如汽车、航空航天和能源，这些行业大量使用难切削材料。切削刀具确保行业技术转移发展该项目通过研究生和本科生（特别是女性和代表性不足的少数族裔）参与研究和教育，为先进制造和工程培养训练有素的劳动力。该项目旨在研究几何约束剪切变形区域如何影响加工过程的力学、动力学和生成的表面完整性。通过额外的约束刀具控制剪切变形区域会导致切屑形成缺乏直接控制。通过原位数字成像以及分析和计算建模对约束切削过程中的切屑变形进行实验分析，以了解约束参数（位置和几何形状）与切削力（力）之间的基本关系。限制剪切变形区域可减少塑性变形和热机械载荷，从而改善表面光洁度、增强微观结构并减少残余应力以及与变形和温度分析的相关性。新知识能够更好地控制生成表面的完整性，还研究了约束工具对过程和加工设备的耦合动力学的影响，这导致了约束工具几何形状的新设计，以控制和抑制高应力。加工过程中的频率自激颤振不稳定性允许以更高的深度、进给和速度加工精密零件，从而实现更高的材料去除率和卓越的表面光洁度。该奖项反映了 NSF 的法定使命，并通过使用评估被认为值得支持。基金会的智力价值和更广泛的影响审查标准。