Machining of Elastomers and Elastomer-Steel Composites

这项拨款为开发加工弹性体和弹性体-钢复合材料的新方法提供资金。将研究几种加工方法，包括使用超锋利刀具的高速铣削，用感应加热工具加工弹性体，以及低温冷却弹性体的加工。对工具-工件相互作用的理解将使用有限元技术来开发，以解决弹性体的大应变和高度变形的弹粘塑性响应。这些模型将用于确定刀具力、工件温度和变形，以及加工弹性体的表面粗糙度作为操作条件和刀具几何形状的函数。将与几个工业伙伴密切合作，开发适当的材料性能数据，以表征在加工中预期的高温和高应变率下弹性体的响应。工具和操作条件导致光滑的表面光洁度和无损坏的零件将被识别，并进行切割测试，以验证基于工具力和表面光洁度的模型。这项研究将导致在高温和低温条件下加工弹性体时切屑形成的基本机制的新认识。这种理解对于确定工具和操作条件至关重要，以提高各种弹性体产品的可加工性，如减震器、隔音和减震器、密封件、轮胎、电气和隔热材料、鞋类、油管以及其他需要高度柔性或可拉伸材料的应用。与传统昂贵且耗时的成型工艺相比，本研究中研究的加工方法为快速生产精密弹性体零件提供了一种实用的替代方案，可用于大量定制应用，成本显著降低。这项研究也为开发新的制造工艺提供了潜力，以实现具有成本效益和环保意识的轮胎回收。

This grant provides funding to develop new methods for machining elastomers and elastomer-steel composites. Several machining methods will be investigated including high speed milling using ultra-sharp cutters, machining of elastomers with induction heated tools, and machining of cryogenically-cooled elastomers. An understanding of the tool-workpiece interaction will be developed using finite element techniques that address the large strain and highly deforming elasto-viscoplastic response of elastomers. The models will be used to determine tool forces, workpiece temperatures and deformation, and surface roughness of a machined elastomer as a function of operating conditions and tool geometry. Appropriate material property data will be developed in close collaboration with several industrial partners to characterize the elastomer response at the elevated temperatures and high strain-rates anticipated in machining. Tools and operating conditions that result in smooth surface finishes and damage-free parts will be identified, and cutting tests will be performed to verify the models based upon tool forces and surface finish.This research will lead to new understanding of the fundamental mechanisms of chip formation during machining of elastomers at both elevated temperatures and cryogenic conditions. This understanding is critical for identifying tools and operating conditions to improve the machinability of a wide range of elastomeric products such as shock isolators, sound and vibration absorbers, seals, tires, electrical and thermal insulators, footwear, tubing, and other applications requiring a highly flexible or stretchable material. As compared with traditional expensive and time-consuming molding processes, the machining methods investigated in this research promise a practical alternative for rapid production of precision elastomeric parts for a multitude of custom applications at significantly lower cost. This research also offers the potential for the development of new manufacturing processes for cost-effective and environmentally conscious tire recycling.