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

由于高应变率变形与摩擦相结合的复杂的金属切削相互作用，目前还没有合适的金属切削模型。在这份职业建议书中，将引入一种创新的有限元模型，以研究在不同的操作条件下：(1)三维显式动态效应，(2)速度-温度相关的摩擦，(3)刀具涂层，(4)刀具切屑-沟槽几何。有限元模拟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的机械加工至关重要。将进行实验以验证模型的有效性。教育战略将包括教学方法的适度改变，并引入以下内容：(1)开发一门工程软件课程，(2)将数值求解技术纳入几门核心机械工程课程，以及(3)在顶峰团队设计项目中使用基于计算机的求解技术。金属切割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基本新的和有用的信息。槽型刀具的有限元分析结果将为获得所需的断屑特性提供指导。教育计划将更好地培养面向团队的工程师，拥有基于计算机的解决问题的技能，这些技能随着时间的推移而不断适应。

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.