Mechanics and dynamics of machining advanced composite materials

先进复合材料加工力学与动力学

• 批准号: RGPIN-2016-04284
• 负责人: Ahmadi, Keivan
• 金额: $ 2.26万
• 依托单位: University of Victoria
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2022
• 资助国家: 加拿大
• 起止时间: 2022-01-01 至 2023-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=760125
• 关键词: Mechanics; dynamics; machining; advanced; composite

Composites offer an outstanding strength to weight ratio and fatigue and corrosion resistance, therefore their application has grown tremendously in a broad spectrum of productsfrom consumer to aerospace. To accommodate the surge in the application of composites, the industry demands high productivity manufacturing methods to convert the material into the final product. Machining operations such as drilling, milling and trimming are usually a critical step in manufacturing composites. These operations are commonly used in finishing and assembly stages and thus poor machining conditions may lead to scraping of the finished product. The ultimate goal of this program is to develop High Performance Machining (HPM) systems to enhance the productivity and robustness of composite machining processes by a) simulation-based optimization of the process, b) appropriate process control and monitoring and c) developing intelligent robotic machining systems. Achieving these objectives will have a transformative effect on current methods of machining composites. For example, in manufacturing the composite structure of a commercial aircraft, more than 70% of the drilling operations are performed manually; such operations can be carried out using automated robotic systems to optimize the speed and robustness of production, also to avoid workplace health and safety hazards such as white finger syndrome due to drill vibrations.The proposed research will contribute to developing HPM systems by characterizing the chip generation process in composite machining and modeling the resulting cutting forces and vibrations. These models will be used in the long term for the optimization, control and automation of the process. Mathematical modeling of the process will be studied by pursuing the following objectives in the next five years: i) characterizing the material failure modes (shear, fracture, etc.) that lead to chip generation in Fiber Reinforced Polymers (FRP), ii) developing the mathematical models of cutting forces in terms of the feed, speed, tool geometry and material's constitutive model, and iii) incorporating the structural flexibility of the tool and workpiece in cutting force models to simulate the vibrations during machining operations. Although the focus of the study in the next five years will be on FRPs, because of their broader industrial applications, modeling will be extended to other types of composites in the long term.Scientific and technological contributions of the program will be complemented by training several Highly Qualified Personnel (HQP), who will receive training on fundamental and applied fields of engineering such as fracture mechanics, dynamics, vibrations, Finite Element Modeling, hands-on experimentation, signal processing and experimental structural dynamics. This training will prepare them to take on leadership roles in academia and industry.

复合材料具有出色的强度重量比以及耐疲劳性和耐腐蚀性，因此其应用在从消费品到航空航天的广泛产品中得到了巨大的增长。为了适应复合材料应用的激增，该行业需要高生产率的制造方法来将材料转化为最终产品。钻孔、铣削和修整等加工操作通常是复合材料制造的关键步骤。这些操作通常用于精加工和装配阶段，因此不良的加工条件可能会导致成品报废。该计划的最终目标是开发高性能加工 (HPM) 系统，通过 a) 基于仿真的过程优化、b) 适当的过程控制和监控以及 c) 开发智能机器人来提高复合材料加工过程的生产率和稳健性加工系统。实现这些目标将对当前复合材料加工方法产生变革性影响。例如，在制造商用飞机的复合材料结构时，70%以上的钻孔操作是由人工完成的；此类操作可以使用自动化机器人系统进行，以优化生产的速度和稳健性，同时避免工作场所的健康和安全危害，例如钻头振动引起的白指综合症。拟议的研究将通过表征芯片来促进 HPM 系统的开发复合材料加工中的生成过程并对产生的切削力和振动进行建模。这些模型将长期用于过程的优化、控制和自动化。将通过在未来五年内实现以下目标来研究该过程的数学模型：i）表征导致纤维增强聚合物（FRP）中碎屑生成的材料失效模式（剪切、断裂等），ii）开发根据进给、速度、刀具几何形状和材料本构模型建立切削力的数学模型，以及 iii) 将刀具和工件的结构灵活性纳入切削力模型中，以模拟加工操作期间的振动。尽管未来五年的研究重点将是玻璃钢，但由于其更广泛的工业应用，从长远来看，建模将扩展到其他类型的复合材料。该计划的科学和技术贡献将通过培训几位专家来补充。高素质人员（HQP），将接受工程基础和应用领域的培训，如断裂力学、动力学、振动、有限元建模、动手实验、信号处理和实验结构动力学。这项培训将为他们在学术界和工业界担任领导角色做好准备。