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

这个CAREER项目的研究重点是对机床、工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。这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，这代表了一种范式的转变，从将两者视为实际上独立的问题。将建立一个遵循滑移线理论的三维机械犁边模型。犁耕模型将由在工业相关过程中使用弯曲切削刃时出现的切屑变形能量模型加以补充。其结果是将特定工艺的物理校准实验替换为仅基于管端车削物理测试数据的预测特定工艺校准伪。然后，它将与颤振水平的解析解合并，首先为线性过程导出，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发展为以项目为基础的经验，包括设计，分析和动手制造部件和简单系统，以及开发机械加工动力学和力学的研究生课程，作为加工动力学和基本过程力学的最新研究的存储库。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池，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、单道次和硬加工）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).