CAREER: Modeling Three-Dimensional Machining Processes for Variable Tool-Chip Interfacial Friction Using Explicit Dynamic Finite Element Techniques

主要由于金属切削的高应变率变形与摩擦相结合的复杂相互作用，仍然没有适当的金属切削模型。 在本职业提案中，将引入一种创新的有限元模型，以在各种操作条件下研究以下内容：（1）三维显式动态效应，（2）速度-温度相关摩擦，（3）切削刀具涂层，和（4）切削刀具切屑槽几何形状。 从有限元模拟中获得的结果将在几个领域提供创新知识，这些领域对于获得高质量和高生产率至关重要。 将进行实验来验证该模型。 教育战略将包括教学方法的适度变化，并引入以下内容：（1）开发工程软件课程，（2）将数值求解技术纳入几个核心机械工程课程，以及（3）在顶点团队设计项目中利用基于计算机的解决方案技术。 金属切削和其他加工过程的成功需要对所涉及的摩擦学行为有全面的了解。 从这项研究中可以获得关于涂层厚度和材料对加工性能的影响的新的和有用的信息。 槽形刀具的有限元分析结果将为获得理想的断屑槽特性提供指导。 该教育计划将更好地培养面向团队的工程师，并具有随着时间的推移而适应的基于计算机的问题解决技能。

Due primarily to the complex interaction of metal cutting which combines high strain rate deformations with friction, there still exists no adequate model of metal cutting. In this Career proposal, an innovative finite element model will be introduced to investigate, under a diverse range of operating conditions, the following: (1) three-dimensional explicit dynamic effects, (2) velocity-temperature dependent friction, (3) cutting tool coating, and (4) cutting tool chip-groove geometry. The results obtained from the finite element simulations will provide innovative knowledge in several areas which are vital for obtaining high quality and productivity in machining. Experiments will be performed to validate the model. The education strategy will incorporate moderate changes in teaching approach and introduce the following: (1) the development of an engineering software course, (2) the incorporation of numerical solution techniques into several core mechanical engineering courses, and (3) the utilization of computer based solution techniques in a capstone team design project. The success of metal cutting and other machining processes requires a complete knowledge of the tribological behavior involved. Substantially new and usable information can be gained from this study about the influence of coating thickness and materials on machining performance. Finite element results on grooved cutting tools will provide guidance for obtaining desired chip-breaker characteristics. The education plan will better prepare engineers that are team oriented, with computer based problem solving skills which are adaptable over time.