GOALI: Development of Comprehensive Drilling Simulation Tool

GOALI研究项目旨在加深对钻头性能、刀具和材料在毛刺和切屑形成上的行为以及孔表面光洁度和直径的更基本的了解。这一理解将被用于开发制造工程工具，以设计和实施精密部件的高效钻孔工艺，如航空航天和汽车零部件。所使用的方法将依赖于加州大学伯克利分校和波音公司的联合合作。将对工艺变量进行详细研究，并开发分析工具(主要是有限元)，以帮助工程师设计在精密制造中应用的最佳钻削方法。这项研究的具体内容包括：1)建立单层钻井的有限元模型，2)对钻头的几何和材料进行评估和建模，3)开发多层钻井的有限元模型和仿真分析，4)开发钻井中毛刺/切屑形成的实验数据库。如果研究成功，本研究将产生一种工艺建模和井眼质量优化的方法，并建立相关的验证数据库，为工程师从设计到工艺规划到工厂现场故障排除提供有效的钻井方法优化的基础。其好处包括：1)简化和标准化类似应用的钻井方法；2)标准化钻井硬件并显著降低库存；3)缩短从工艺设计到生产过渡的周期时间(60%-80%)；4)为现有和新工艺改进创造机会。这将带来更好的产量、更高的质量和更低的成本。学生在伯克利的参与将带来极好的培训体验，并为行业职业生涯或额外学习做好准备。

The objective of this Grant Opportunity for Academic Liaison with Industry (GOALI) research project is to develop a more fundamental understanding of drill performance, behavior of cutting tools and materials on burr and chip formation, and hole surface finish quality and diameter. This understanding will be used to develop manufacturing engineering tools for designing and implementing efficient drilling processes in precision components, such as aerospace and automotive parts. The approach used will rely on joint collaboration between the University of California at Berkeley and Boeing. A detailed study of the process variables will be made and analytical tools (finite element, primarily) developed to aid engineers in designing optimal drill methods for application in the precision manufacturing. Specific elements of this study are: 1) develop a finite element model of single layer drilling, 2) evaluate and model drill bit-geometry and materials, 3) develop a finite element model and simulation analysis of multi-layered drilling, and 4) development of an experimental database on burrs/chips formation in drilling.If successful, this research will result in a methodology for process modeling and optimization of hole quality and an associated database of verification that will be the basis for engineers from design to process planning to factory floor trouble-shooting for effective drilling method optimization. The benefits will include: 1) streamline and standardize drilling methods for similar application, 2) standardize drill hardware and significant inventory reduction, 3) reduce cycle time (60 - 80%) from process design to production transition, and 4) create opportunity for existing and new process improvement. This will result in better yield, higher quality and reduced costs. Student participation at Berkeley will result in an excellent training experience and preparation for industry careers or additional study.