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

铣削过程中的材料去除可能是稳定的，也可能是振荡的，这取决于材料、几何形状和参数，如切削深度和切削速度。材料去除的动态影响成品表面的质量。这反映在芯片的形式，可能是光滑的或分段的。这个GOALI项目的目标是推导出描述这些行为及其对参数的依赖关系的模型，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将被放宽，以允许对实验观察到的更多现象和参数依赖关系进行建模。为了验证升级后的模型，实验将在NIST制造工程实验室的高速铣床上进行正交和传统切削几何。切割将使用安装在旋转主轴上的测功机进行监测，该测功机带有射频遥测、高带宽红外温度传感器和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是对有限元分析和实验的补充。这些模型将提供对加工参数对切削过程行为的影响的理解和广泛的直觉。这项工作对汽车和飞机零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.