GOALI/IUCP: Dynamic Analysis of High-Performance Drilling and Reaming Systems for Aerospace Manufactuirng

该项目的目标是分析高精度和高速钻孔和铰孔中刀具振动和孔圆度误差的原因;并将分析结果应用于航空航天制造的刀具和工艺设计。 这项工作是圣路易斯华盛顿大学的研究人员和波音公司的工程师们共同努力的结果。 在金属切削中，振动是由刀具主切削刃上的力以及刀具侧面和间隙面上的冲击和摩擦激发的。 该项目将开发精确的扩孔和钻孔模型，包括在高速自动化工作站中钻孔。这些模型将考虑弯曲、轴向和扭转运动，以及这些变形对切削力和摩擦的影响。将从这些模型中获得解析解和数值解，以解释振动的主要原因。 将发展近似非线性方法来求出钻井中振动的振幅和稳定性。实验工作将在波音公司的先进制造研发设施进行，以验证分析和数值计算结果。 将在物理机器上进行切削和振动试验，为数学模型提供参数，并验证理论预测。 该项目解决了需要了解精密制孔过程，这是至关重要的机身制造。在生产一架飞机的过程中，可能要钻一百万个或更多的孔。自动化装配、高速钻孔和先进的刀具设计有可能大幅提高生产率并降低成本，但前提是必须了解孔加工的复杂动力学。

The goals of this Grant Opportunities for Academic Liaison with Industry (GOALI) project are to analyze the causes of tool vibration and hole roundness error in high-precision and high-speed drilling and reaming; and, to apply the results of this analysis to tool and process design for aerospace manufacturing. The work is a collaborative effort between researchers at Washington University in St. Louis and engineers at the Boeing Company. In metal cutting, vibrations are excited by forces on the tool's main cutting edges, as well as by impact and friction on the sides and clearance faces of the tool. The project will develop accurate models of reaming and drilling, including drilling in high-speed, automated stations. These models will take into account bending, axial, and twisting motion, and the effects of these deformations on cutting forces and friction. Analytical and numerical solutions will be obtained from these models to explain the major causes of vibration. Approximate nonlinear methods will be developed to find the amplitude and stability of vibrations in drilling. Experimental work will be conducted at Boeing's Advanced Manufacturing R&D facilities to validate the analytical and numerical results. Cutting and vibration tests on physical machines will be performed to provide parameters for mathematical models and to validate theoretical predictions. This project addresses the need to understand the precision hole-making process, which is critical to airframe manufacturing. A million or more holes may be drilled in the production of a single aircraft. Automated assembly, high-speed drilling, and advanced tool designs have the potential to dramatically increase productivity and decrease costs, but only if the complex dynamics of hole-making are understood.