High performance machining of lightweight composites and advanced aerospace alloys

轻质复合材料和先进航空航天合金的高性能加工

• 批准号: RGPIN-2017-05623
• 负责人: Balazinski, Marek
• 金额: $ 2.26万
• 依托单位: École Polytechnique de Montréal
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2018
• 资助国家: 加拿大
• 起止时间: 2018-01-01 至 2019-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=644529
• 关键词: performance; machining; lightweight; composites; advanced

Modern aircraft should ensure reduced fuel consumption as well as reduced CO2, NOx, and noise emission. To this end, airframe and engine manufacturing improvements are necessary. This implies the use of lightweight materials for airframes and engines and advanced turbine materials for discs and blades. The most widely used advanced high strength alloys for airframes are aluminium and refractory alloys and lightweight composite materials like Fiber Reinforced Plastic (FRP), Carbon or Glass Fiber Reinforced Polymer (C/GFRP), and Titanium Metal Matrix Composites (TiMMCs), and for aircraft engines, nickel and titanium alloys. These materials also have great potential for the automotive and biomedical sectors.***After consulting with industry (Pratt&Whitney, RTI, Alcoa, and Bombardier), with this discovery grant, we will focus on evaluation of two materials: Titanium Metal Matrix Composites (TiMMCs) and Carbon Fiber Reinforced Polymer (CFRP). Our preliminary research and a literature review give us the opportunity to define a working hypothesis:***1. It is possible to increase the entire tool life by at least 20% by appropriate control of initial cutting conditions and initial tool wear.***2. Part performance in service can be predicted more accurately using new surface roughness analysis methods and parameters better adapted to composite materials CFRPs, namely using fractal analysis.***3. Tool life estimations can be improved using survival analysis, fractal analysis, and tool wear monitoring based on pattern recognition and Logical Analysis of Data.***Initial cutting conditions, initial cutting tool wear, and their impact on entire tool life when machining TiMMCs have never been studied before. Our preliminary works also show that the application of chaos theory and fractals for analysis of initial cutting conditions and surface roughness is very promising. The theory of fractals has already proven highly effective in many engineering and technology applications and can dramatically change research methods in machining. Consequently, the originality of this work lies in the use of chaos theory and fractals as an approach to understand cutting tool wear and to generate new, meaningful surface roughness parameters for plastics containing fibers (CFRPs). This new approach can also greatly improve the diagnosis and monitoring of cutting tools and the optimization of cutting parameters. We do not claim to revolutionize machining theory but we intend to bring to light a new perspective for the analysis of machining processes.***OBJECTIVES:***The main goal of this research program is to provide new insights on the machinability of new advanced aerospace alloys, Carbon or Glass Fiber Reinforced Polymers (C/GFRP), tool wear modeling and analysis and develop a new surface analysis method and roughness parameters better adapted to composite materials.**

现代飞机应确保降低燃油消耗以及二氧化碳、氮氧化物和噪音排放。为此，必须改进机身和发动机制造。这意味着在机身和发动机上使用轻质材料，在盘和叶片上使用先进的涡轮材料。用于机身的最广泛使用的先进高强度合金是铝和耐火合金以及轻质复合材料，例如纤维增强塑料（FRP）、碳或玻璃纤维增​​强聚合物（C/GFRP）和钛金属基复合材料（TiMMC），以及飞机发动机、镍和钛合金。这些材料在汽车和生物医学领域也具有巨大潜力。***在与业界（普惠公司、RTI、美国铝业公司和庞巴迪公司）协商后，利用这项发现资助，我们将重点评估两种材料：钛金属基复合材料（ TiMMC）和碳纤维增强聚合物（CFRP）。我们的初步研究和文献综述使我们有机会定义一个工作假设：***1。通过适当控制初始切削条件和初始刀具磨损，可以将整个刀具寿命延长至少 20%。***2。使用新的表面粗糙度分析方法和更适合复合材料CFRP的参数，即使用分形分析，可以更准确地预测零件的使用性能。***3。使用基于模式识别和数据逻辑分析的生存分析、分形分析和刀具磨损监测可以改进刀具寿命估计。***加工 TiMMC 时，初始切削条件、初始切削刀具磨损及其对整个刀具寿命的影响以前从未研究过。我们的前期工作还表明，应用混沌理论和分形来分析初始切削条件和表面粗糙度是非常有前途的。分形理论已被证明在许多工程和技术应用中非常有效，并且可以极大地改变机械加工的研究方法。因此，这项工作的原创性在于使用混沌理论和分形作为理解切削刀具磨损的方法，并为含纤维塑料 (CFRP) 生成新的、有意义的表面粗糙度参数。这种新方法还可以极大地改善切削刀具的诊断和监控以及切削参数的优化。我们并不声称要彻底改变加工理论，但我们打算为加工过程分析提供新的视角。***目标：***本研究计划的主要目标是提供关于新材料的可加工性的新见解。先进的航空航天合金、碳纤维或玻璃纤维增​​强聚合物 (C/GFRP)、刀具磨损建模和分析，并开发更适合复合材料的新表面分析方法和粗糙度参数。**