GOALI: Development of Comprehensive Drilling Simulation Tool

该学术联络与工业研究项目（GOALI）的目标是对钻头性能、切削工具和材料在毛刺和切屑形成方面的行为，以及孔表面光加工质量和直径有更基本的了解。这种理解将用于开发制造工程工具，用于设计和实施精密部件（如航空航天和汽车部件）的高效钻孔工艺。所采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。将对过程变量进行详细研究，并开发分析工具（主要是有限元），以帮助工程师设计适用于精密制造的最佳钻削方法。本研究的具体内容为：1)建立单层钻井的有限元模型；2)对钻头几何形状和材料进行评估和建模；3)建立多层钻井的有限元模型和仿真分析；4)建立钻井过程中毛刺/切屑形成的实验数据库。如果成功，这项研究将产生一种工艺建模和孔质量优化的方法，以及一个相关的验证数据库，这将成为工程师从设计到工艺规划再到工厂车间故障排除的基础，从而实现有效的钻井方法优化。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减少库存；3)减少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。这将导致更好的产量，更高的质量和降低成本。学生在伯克利的参与将导致一个优秀的培训经验和准备行业的职业生涯或额外的学习。

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.