Modeling and Control of Subsurface Damage During the Grinding of Intermetallic Compounds

DMI-9812967库尔菲斯金属间化合物(IMCs)以其轻质、高强度、高熔点和优异的抗氧化性而闻名。为了实现这些先进材料的潜力，必须考虑几个问题，包括机械加工等二次工艺的开发，以及为保证质量、可靠性和成本而进行的精确工艺控制。本研究有三个主要目的：确定各种磨削参数对金属间化合物的影响，建立损伤描述的机理模型，并通过实验方法对损伤模型进行验证。为了建立磨削参数与材料塑性变形之间的经验模型，将在一台仪表化程度很高的磨床上进行一系列析因实验。这些数据集将用于开发和验证该模型。模型的开发将基于对应用于IMC的磨削过程物理(包括机械和热过程特性)的理解。一旦模型被开发和验证，将设计和实现一个控制器来操纵控制参数以达到期望的结果。此外，还将开发用于定义工艺参数轨迹的更高级别的控制器，该控制器也涉及经济考虑因素(例如，加工时间)。该项目的成功完成将有助于更好地了解磨削IMC的物理原理、损伤形成的机理模型以及实现所需磨削结果的有价值的控制策略。与几家工业公司的合作提供了良好的协同效应和机构资源共享。该项目应该特别对航空航天、汽车和化工行业产生影响。

DMI-9812967Kurfess Intermetallic compounds (IMCs) are noted for their light weight, high strength, high melting point, and excellent oxidation resistance. To realize the potential of these advanced materials several issues must be considered, including the development of secondary processes such as machining and precise process control for quality assurance as well as reliability and cost. The research has three major objectives: determining the influence of various grinding parameters on intermetallic compounds, developing a mechanistic model for damage formulation, and verification of the damage model via experimental methods. To develop an empirical model relating grinding parameters and resulting plastic deformation in the material, a set of factorial experiments will be conducted on a highly instrumented grinder. These data sets will be used to develop and verify the model. The model development will be based on the understanding of the grinding process physics (including both the mechanical and thermal process characteristics) applied to IMCs. Once the model has been developed and validated, a controller will be designed and implemented that manipulates the control parameters to achieve the desired results. Furthermore, a higher-level controller for defining process parameter trajectories will be developed that also addresses economic considerations (e.g., machining time). Successful completion of this project will lead to a good understanding of the physics of grinding IMCs, a mechanistic model for damage formulation, and a valuable control strategy for achieving desired grinding results. The collaboration with several industrial firms provides excellent synergy and sharing of institutional resources. The project should impact especially on the aerospace, automotive and chemical sectors.