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

该CAREER项目的研究重点是机床，刀具和加工过程的综合分析，以支持系统方法来开发，规划和诊断加工系统。 这就需要一个综合的分析工具，将详细的切削力学和分析加工动力学结合起来，这代表了范式的转变，不再将两者视为几乎独立的问题。 一个3-D机械边缘犁模型将制定，使其坚持滑移线理论。 犁削模型将由切屑变形能模型补充，该模型在使用工业相关工艺中看到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过程特定校准伪替代过程特定物理校准实验。 然后将其与颤振水平的解析解合并，首先导出线性过程，然后扩展到过程非线性。教育活动将包括将机械设计课程重新开发为基于项目的经验，包括设计，分析和动手制造组件和简单系统，以及开发关于动力学和机械加工的研究生课程，作为机械加工动力学和基础工艺力学最新研究的知识库。 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的数量，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).