SBIR Phase II: Residual Stress and Part Distortion Prediction in Machined Workpiece Surfaces

该小型企业创新研究（SBIR）第二阶段项目将开发和验证行业所需的预测能力，以通过控制机加工引起的应力，同时减少航空航天和汽车零件的变形，从而大幅提高机加工工件的质量。第二阶段的目标是继续开发和验证预测残余应力和零件变形的分析工具。其目标是为工业提供一种有效的分析工具，以方便和经济地预测和防止零件变形，降低测试试验、零件报废和上市时间的成本，提高产品质量和竞争力。这项技术的商业和更广泛的影响将为工业提供预测和防止由于加工引起的残余应力引起的零件变形的能力。目前的技术依赖于测试和经验，在技术上不够充分，也不符合成本效益。航空航天零件（大型、整体式、薄壁且昂贵）和关键的汽车动力系统应用是典型的例子，这些应用需要平坦的表面来保持燃油效率、部件寿命和较低的排放。显著的影响将是制造成本、更低的废料、更高的生产率、更短的上市时间以及更高的产品质量和性能。

This Small Business Innovation Research (SBIR) Phase II project will develop and validate the predictive capability industry needs to dramatically improve machined workpiece quality by controlling machining induced stresses while simultaneously reducing distortion in aerospace and automotive parts. The objective for Phase II will be to continue the development and verification of analysis tools for predicting residual stress and part distortion. The goal is to supply industry with a validated analytical tool to easily and economically predict and prevent part distortion-reducing costs due to testing trials, part scrap, and time-to-market, increasing product quality and competitiveness.The commercial and broader impacts of this technology will be provide industry with the ability to predict and prevent part distortion due to machining induced residual stress. Current techniques, which rely upon testing, and experience are not sufficient technically nor are they cost effective. Aerospace parts (large, monolithic, thin-walled, and expensive) and critical automotive powertrain applications, which demand flat surfaces to maintain fuel efficiency, component life, and lower emissions, are typical examples. A significant impact will be to manufacturing costs, lower scrap material, higher productivity, lower time-to-market, and increased product quality and performance.