GOALI/IUCP: Nonlinear Dynamic Models of Material Flow in High-Speed Machining

DMI-9800323 Feeny 铣削过程中的材料去除可能是稳定的或振荡的，具体取决于材料、几何形状以及切削深度和切削速度等参数。材料去除的动态影响成品表面的质量。这反映在碎片的形式上，碎片可以是光滑的，也可以是分段的。 该 GOALI 项目的目标是导出描述这些行为及其对参数的依赖性的模型，并通过实验验证模型。现有二维材料去除模型中的基本假设（解释了芯片分割的开始）将被放宽，以允许对实验观察到的更多现象和参数依赖性进行建模。为了验证升级后的模型，将在 NIST 制造工程实验室的高速铣床上使用正交和传统切削几何形状进行实验。将使用安装在旋转主轴上的测功机进行监控，该测功机配有射频遥测、高带宽红外温度传感器以及可能的超声波发射传感器。 切削力学和动力学预测模型的发展补充了有限元分析和实验。 这些模型将为加工参数对切削过程行为的影响提供理解和广泛的直觉。这项工作对于汽车和飞机零部件的制造具有实际价值。

DMI-9800323 Feeny Material removal during milling may be steady or oscillatory, depending on materials, geometry, and parameters such as depth of cut and cutting speed. The dynamics of material removal affects the quality of the finished surface. This is reflected in the form of chips which may be smooth or segmented. The objective of this GOALI project is to derive models that describe these behaviors and their dependencies on parameters, and verify the models with experiments. Basic assumptions in an existing two-dimensional model for material removal, which accounts for the onset of chip segmentation, will be relaxed to allow the modeling of more phenomena and parameter dependencies which are observed experimentally. To verify the upgraded model, experiments are to be conducted with orthogonal and conventional cutting geometry on a high-speed milling machine at the Manufacturing Engineering Laboratory at NIST. Cutting will be monitored using a rotating spindle-mounted dynamometer with radio-frequency telemetry, high-bandwidth infrared temperature sensors and possibly ultrasonic emission sensors. The development of predictive models of cutting mechanics and dynamics complements finite-element analyses and experiments. These models will provide understanding and broad intuition on the effect of machining parameters on cutting process behavior. The work is practically valuable to the manufacture of automotive and aircraft parts.