PREMISE: Predictive Modeling of Environmental Impact and Tool Performance in Near Dry Turning

该项目由产品实现和环境制造创新系统（前提）计划支持，旨在开发对车削操作中近干润滑参数的分析理解和预测建模能力或定量规划。目标是控制空气质量和工具磨损，以实现环境和生产力的任务。本项目利用机械加工科学、流体力学、传热理论和液体雾化原理，建立了一套预测模型，以估计气溶胶浓度和刀具磨损率作为近干润滑参数和切削条件的函数。为此，将研究混合润滑或边界润滑下的温度和应力分布；通过蒸发、飞溅和耗散机制产生切削液气溶胶将被检查；并定量评价刀具因粘附、磨损和扩散而产生的体积磨损率。非加工试验的实验校准和加工试验的全范围验证将随着理论的发展而发展。该项目的结果将为近干加工性能的评估、量化和优化提供所需的科学基础。该项目的更广泛影响包括由此产生的科学理解的可扩展性，以支持工艺优化，基于活动的成本计算，以及对各种零件完整性问题，各种浪费问题和不同加工配置的生命周期分析。该项目还旨在将研究纳入教育计划，鼓励代表性不足的学生群体的参与，并涉及多个行业部门的合作，包括流体点胶系统供应商、工具制造商、机器制造商和技术最终用户。这项研究的成功完成将为未来全面的、以团队为基础的研究项目提供机会。

This project is supported by the Product Realization and Environmental Manufacturing Innovative Systems (PREMISE) Program to develop the analytical understanding and predictive modeling capability or the quantitative planning of near dry lubrication parameters in turning operations. The targets are set on the control of air quality and tool wear in achieving environmental and productivity missions. This project utilizes machining science, fluid mechanics, heat transfer theories, and liquid atomization principles to develop a set of predictive models that estimate the aerosol concentration and the tool wear rate as functions of near dry lubrication parameters and cutting conditions. To this end, the temperature and stress distributions under mixed or boundary lubrication will be developed; the generation of cutting fluid aerosol through evaporation, splash, and dissipation mechanisms will be examined; and the volumetric wear rate of cutting tool due to adhesion, abrasion, and diffusion will be quantitatively evaluated. Experimental calibration in non-machining tests and full-range validation in machining tests will follow the theoretical development.The results of the project will provide a scientific infrastructure needed for the evaluation, quantification, and optimization of near dry machining performances. The broader impacts of the project include the extendibility of the resulting scientific understanding to support process optimization, activity based costing, and life cycle analysis of a wide range of part integrity issues, various waste concerns, and in different machining configurations. The project will also aims to integrate research into educational programs, to encourage the involvement of underrepresented student groups, and to involve the collaboration of several industry sectors, including fluid dispensing system vendors, tool manufacturers, machine makers, and technology end users. The successful completion of this study will open up opportunities for future full-scale, team-based research programs to follow.