Mechanics-Based Analysis of Small-Scale Surface Generation in Hard-Tool Machining

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9522809 Endres The final size and shape of precision ceramic components are usually generated by grinding, a process that can handle the high strength of these materials, but risks causing micro cracking that can lead to functional failure of these parts. The alternative that will be investigated in this research is termed hard-tool machining, where a controlled geometry cutting edge is used to machine ceramics. Models that are based on the more realistic large radius cutting edges found on real tooling, modeling the material removal mechanism for ceramics by fracture, rather than plasticity, and how the heat generated may affect the machined surface layer will be considered by and interdisciplinary team of experts in machining dynamics and kinematics, micro mechanics, fracture mechanics and tribology. Modeling will consider: mechanics at the micro scale to predict the chip separation, the numerical methods, and the resultant topography and stress state related to the integrity of the newly generated surface. An experimental program to verify the modeling results with a special purpose experimental setup, as well as techniques like scanning electron microscopy, will be used to verify and improve the model. The major impact of this research will be in a fundamental and more detailed model for machining ceramics by machining, that can increase the productivity and reduce the cost of high performance ceramic materials The model is need to supplement the experimental work that would normally be necessary to evolve tools and systems that are needed to enable broader use of high performance ceramic materials. ***