CAREER: Merging Dynamics and Mechanics for Integrated Machine-Tool, Tooling and Process Analysis

DMI-9734147结束了这个职业项目的研究重点是机床、刀具和加工过程的综合分析，以支持加工系统的开发、规划和诊断的系统方法。这需要一个综合的分析工具，将详细的切割力学和分析的加工动力学结合在一起，这代表着范式的转变，不再将两者视为几乎独立的问题。将建立一个符合滑移线理论的3-D机械式犁边模型。犁削模型将得到一个切屑变形能模型的补充，该模型在使用工业相关工艺中所见的弯曲切削刃时存在。其结果是用仅基于管端车削物理测试数据的预测的特定于工艺的校准伪取代了特定于工艺的物理校准实验。然后将其与颤振水平的解析解合并，该解析解首先针对线性过程推导，然后扩展以考虑过程的非线性。教育活动将包括将机械设计课程重新发展为以项目为基础的经验，包括部件和简单系统的设计、分析和实践制造，以及开发机械加工动力学和力学研究生课程，作为机械加工动力学和基本过程力学最新研究的储存库。用于性能和风险评估的分析动力学解决方案的开发增加了分析工具库，并允许工业用户减少校准测试。由此产生的科学基础的进步将使新兴加工实践(高速、单程和硬加工)的经济实施成为可能。

DMI-9734147 Endres The research focus of this CAREER project is integrated analysis of the machine tool, tooling, and machining process in support of a systems-approach to the development, planning and diagnosis of machining systems. This requires a comprehensive analysis tool that merges detailed cutting mechanics and analytical machining dynamics, which represents a shift in paradigm from looking at the two as virtually separate problems. A 3-D mechanistic edge ploughing model will be formulated such that it adheres to slip-line theory. The ploughing model will be complemented by a model of the cut-chip deformation energy that is present when using curved cutting edges seen in industrially relevant processes. The result is the replacement of process-specific physical calibration experiments with predicted process-specific calibration pseudo-based solely on tube-end turning physical test data. It will then be merged with an analytical solution for chatter level, derived first for a linear process and then extended to account for process nonlinearity. Educational activities will include the redevelopment of a mechanical design course into a project-based experience including design, analysis and hands-on manufacture of components and simple systems, as well as the development of a graduate course on dynamics and mechanics of machining as a repository for the latest research in machining dynamics and fundamental process mechanics. The development of analytical dynamics solutions for performance and risk assessment increases the pool of analysis tools and allows industrial users to reduce calibration testing. The resulting advances in the science base will make possible economic implementation of emerging machining practices (high-speed, single-pass and hard machining).