3D Laser Forming of Doubly Curved Shapes: Process Prediction and Synthesis

许多工程结构的表面被设计成双曲面形状，以满足诸如水动力、美学或结构等功能要求。实验表明，激光成形双曲面等三维形状是可行的，但成形精度问题需要通过提高工艺预测能力来更好地理解。同样，简单形状激光成形的工艺综合方案在三维激光成形方面也有待进一步发展。该项目旨在显著推进LF技术的知识状态，从理想化到更实用的形状，从分析到综合。建模和合成工作将伴随着一个实验程序，包括成型前和成型后的微观结构和力学性能表征。其他高温变形过程将能够利用项目中开发的改进的理解和合成能力。实际上，该项目的成功将为制造高性能但传统上难以成型的材料开辟新的机会，从而导致创新应用，从而开辟新的设计选择。可靠的工艺合成方案的发展将使该工艺进入工业应用，作为高产量的快速成型工具和低产量钣金加工的灵活制造工具。由于钣金加工非常普遍，其结果将对经济和行业竞争力产生重大影响。这个项目的结果将被纳入研究生水平的课程。将努力让本科生参与进来，并从传统上代表性不足的背景中识别和招收合格的学生。

Surfaces of many engineering structures are designed as doubly curved shapes to fulfill functional requirements such as hydrodynamic, aesthetic, or structural. Experiments have shown that it is feasible to laser form 3D shapes such as doubly curved shapes, but forming accuracy issues need to be better understood via enhanced process prediction capability. Similarly, the process synthesis schemes developed for laser forming (LF) of simple shapes need further advancement for 3D LF process. This project is aimed at significantly advancing the state of knowledge LF technology, from idealized to more practical shapes, and from analysis to synthesis. The modeling and synthesis efforts will be accompanied by an experimental program including pre- and post-forming microstructure and mechanical property characterizations. Other high temperature deformation processes will be able to leverage upon the improved understanding and synthesis capabilities to be developed in the project. Practically, the success of the project will open-up new opportunities for manufacturing of high performance but conventionally hard-to-form materials, leading to innovative applications, thus opening new design options. The development of reliable process synthesis schemes will enable the process make its way to industrial applications, as a rapid prototyping tool for high production volume and a flexible manufacturing tool for low production volume sheet metal working. The results will have a significant impact on the economy and industry competitiveness since sheet metal working is so pervasive. Results from this project will be integrated into a graduate level course. Efforts will be made to involve undergraduate students, and to identify and recruit qualified students from traditionally underrepresented backgrounds.